Abstract:
A water meter enclosure includes a non-metallic cover defining an interior cavity shaped to accept a metering device; a metal ring including threads for connection to a piping system; and an annular lip contacting a distal end of the metal ring to retain the metal ring in spatial relationship between the non-metallic cover and the annular lip.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of currently pending U.S. patent application Ser. No. 13/220,739, filed Aug. 30, 2011, which is a continuation of U.S. patent application Ser. No. 12/947,272, filed Nov. 16, 2010, issued as U.S. Pat. No. 8,047,072, which is a continuation of U.S. patent application Ser. No. 12/356,240, filed Jan. 20, 2009 issued as U.S. Pat. No. 7,854,165, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/022,088, filed Jan. 18, 2008, all of which are hereby incorporated herein in their entirety by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention generally relates to flow meters and more particularly to improved plastic water flow meters for commercial and residential use. 
         [0004]    2. Description of Related Art 
         [0005]    Water meters are designed to measure the volume of water usage or the volume of water flow. Water meters can be used in both commercial and residential settings, and they can be utilized at a water source, a point of water usage, or anywhere in between. Typically, water meters are manufactured from one of two types of material: metal or plastic. The trend with water meters is towards the use of plastic meters, as opposed to metal meters. One reason for this trend is that many jurisdictions now require zero lead content in the water supply and accordingly, meters in contact with the water supply also need to have zero lead content. Plastic meters satisfy this zero lead content requirement. 
         [0006]    Generally, a water meter possesses threaded inlets and outlets to facilitate the connection between the water meter and the water system. Plastic water meters generally utilize plastic threads, but water systems typically employ metal threads for the mating connections with water meters. Accordingly, the plastic threads have a tendency to strip or cross thread during installation. Therefore, there is a desire for a plastic water meter with improved inlet and outlet connectivity. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The following summary is not an extensive overview and is not intended to identify key or critical elements of the apparatuses, methods, systems, processes, and the like, or to delineate the scope of such elements. This Summary provides a conceptual introduction in a simplified form as a prelude to the more-detailed description that follows. 
         [0008]    In one embodiment of the present invention, a water meter is provided. The water meter may include a plastic top cover defining an interior cavity shaped to accept a metering device, in which the top cover further defines at least one spud defining a bore in communication with the interior cavity; a metering device positioned in the interior cavity; a bottom cover engaging the top cover and enclosing the metering device within the interior cavity; and at least one connector assembly engaging the at least one spud. The connector assembly may include a plastic spud insert having a first end and a second end, in which the plastic spud insert may include an engagement portion proximate the first end engaging the spud, an annular lip portion positioned proximate the second end and extending outwardly, and a collar portion having a circumferential profile and positioned intermediate the engagement portion and lip portion. The assembly may also include a metal ring having an inner surface and outer surface, in which threads may be formed on the outer surface and the inner surface may have a profile complementary with the profile of the collar, the metal ring may be positioned proximate the lip portion with the inner surface engaging the collar portion, and the circumferential profile of the collar portion and the complementary profile of the metal ring may be configured to discourage relative relational movement. In alternative embodiments, the water meter may include an inlet spud and an outlet spud and an inlet connector assembly and an outlet connector assembly, in which each connector assembly may engage its respective inlet spud or outlet spud. In such embodiments, the inlet spud may be situated approximately 180 degrees opposite the outlet spud. In regard to the materials that makeup the components of the connector assembly, the plastic top cover and/or the plastic spud insert may be styrene, polystyrene, nylon, or glass reinforced thermoplastic, among other materials, and the metal ring may be brass, bronze, a brass derivative, a bronze derivative, or stainless steel, among other materials. Furthermore, the metering device included in the water meter may be a nutating disk displacement flow meter. Even more, the engagement portion of the plastic spud insert may engage the spud by a mild interference fit and may be secured to the spud by spin welding, solvent welding, sonic welding, or by an adhesive, among other methods. Additionally, the circumferential profile of the collar may define various shapes, including a shape having at least one linear section, a shape having a plurality of linear sections, and a substantially oval shape, among other shapes. Furthermore, the inner surface of the metal ring may engage the collar portion by a key-fit arrangement. 
         [0009]    In another embodiment of the present invention, a connector assembly for use with a plastic device having a spud defining a bore is provided. The assembly may include a plastic spud insert having a first end and a second end, in which the plastic spud insert may include an engagement portion proximate the first end configured to engage with the bore, an annular lip portion positioned proximate the second end and extending outwardly, and a collar portion having a circumferential profile and positioned intermediate the engagement portion and lip portion. The assembly may also include a metal ring having an inner surface and outer surface, in which threads may be formed on the outer surface and the inner surface may have a profile complementary with the profile of the collar, the metal ring may be positioned proximate the lip portion with the inner surface engaging the collar portion, and the circumferential profile of the collar portion and the complementary profile of the metal ring may be configured to discourage relative relational movement. The circumferential profile of the collar may define various shapes, including a shape having at least one linear section, a shape having a plurality of linear sections, and a substantially oval shape, among other shapes. Furthermore, the inner surface of the metal ring may engage the collar portion by a key-fit arrangement. As for the materials that makeup the components of the connector assembly, the plastic spud insert may be styrene, polystyrene, nylon, or glass reinforced thermoplastic, among other materials, and the metal ring may be brass, bronze, a brass derivative, a bronze derivative, or stainless steel, among other materials. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0010]    Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
           [0011]      FIG. 1  is an exploded view of a plastic water meter  10  according to one embodiment of the present invention. 
           [0012]      FIG. 2  is an exploded view of the housing assembly  20  shown in  FIG. 1 . 
           [0013]      FIG. 3  is an exploded, cross-section view of a plastic water meter  10  according to one embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
         [0015]    Various embodiments of the present invention provide improved plastic water meters that address issues known in the art, some of which are discussed above.  FIG. 1  illustrates a plastic water meter  10  according to one embodiment of the present invention. This embodiment may include a water meter housing assembly  20  that may enclose a metering device  40  and a strainer  50 . The metering device  40  and the strainer  50  may be positioned inside the housing assembly  20 , and a bottom cover  60  and an o-ring  55  may enclose them within the housing assembly  20 . 
         [0016]    Referring to  FIGS. 2 and 3 , the housing assembly  20  may include a top cover  21  and two connector assemblies  24 A, B. Each connector assembly  24 A, B may include a plastic spud insert  26 A, B and a metal ring  25 A, B, and one connector assembly may function as an inlet connector assembly  24 A and the other connector assembly may function as an outlet connector assembly  24 B. Additionally, the top cover  21  may include an integrated inlet spud  23 A and an integrated outlet spud  23 B. The top cover  21  and the two spud inserts  26 A, B may be made from various types of plastic or high-strength polymer materials, including styrene, polystyrene, nylon, or the like. In a preferred embodiment, the top cover  21  and the two spud inserts  26 A, B may be composed of glass reinforced thermoplastic. Factors that may be considered when selecting a material include working pressures of the meter, and working temperature ranges. 
         [0017]    The top cover  21  may be substantially cylindrical in shape with an integrated top face portion  22 , although those skilled in the art will recognize that the top cover  21  may take other shapes. The bottom of the top cover  21  remains open, thus forming an aperture that leads to the interior cavity  31  of the top cover  21 . 
         [0018]    Proximate the bottom of the top cover  21  may be external threads  30 , which may enable the bottom cover  60  to engage to the top cover  21 . In use, the top cover may flex outwards because of pressure in the system thereby causing the internal threads in the top cover to be urged against the complementary threads on the bottom cover. In other embodiments, the top cover may include internal threads designed to engage external threads on the bottom cover, 
         [0019]    One advantage of the external bottom threads  30  provided in various embodiments of the present invention may be that external bottom threads  30  are easier to manufacture than internal bottom threads. As will be understood by those skilled in the art, forming internal threads requires an insert mold, while forming external threads does not. In some cases, an additional manufacturing step may be required to remove the internal thread mold insert, which may reduce the efficiency of the molding process. 
         [0020]    In the illustrated embodiment, the top cover  21  may include an integrated inlet spud  23 A, through which water enters the interior cavity  31  defined by the top cover  21 , and an integrated outlet spud  23 B, through which water exits the top cover  21 . The inlet spud  23 A and outlet spud  23 B may be in communication with the interior cavity  31  of the top cover  21 . Also, the inlet spud  23 A and the outlet spud  23 B may be each designed to receive and engage a portion of the spud insert  26 A, B. 
         [0021]    Both the inlet spud  23 A and the outlet spud  23 B protrude substantially perpendicularly from the exterior of the top cover  21 , with the outlet spud  23 B situated approximately 180 degrees around the exterior of the top cover  21  from the inlet spud  23 A. As will be understood by those of skill in the art, the inlet spud  23 A and outlet spud  23 B may have a relative orientation other than 180 degrees. 
         [0022]    The spuds  23 A, B may be substantially similar to each other and may have a substantially cylindrical in shape. Each spud  23 A, B defines an axial bore with a proximate orifice that opens through the wall of the top cover  21  into the interior cavity  31  of the top cover  21  and a distal orifice that opens away from the top cover  21 . The proximate orifice and distal orifice of each spud  23 A, B may be substantially circular in shape. In alternative embodiments of the present invention, each spud  23 A, B, may not protrude from the exterior of the top cover  21 , but may instead be an orifice in the exterior of the top cover  21 . 
         [0023]    The bores defined by the inlet spud  23 A and the outlet spud  23 B may be each sized to receive a spud insert  26 A, B respectively, and each spud insert  26 A, B may include an externally threaded metal ring  25 A, B. A purpose of the threaded metal rings  25 A, B may be to facilitate connection of the water meter to a water system, which generally utilizes metal threads for the connection to the water meter. Each spud insert  26 A, B may be substantially cylindrical in shape with a bore formed therein to allow the passage of water. 
         [0024]    Each spud insert  26 A, B may include a first end proximate to the top cover  21  and a second end distal the top cover  21 . Proximate the second end of each spud insert  26 A, B may be an annular lip portion or rim  29 A, B that extends outwardly. Each threaded metal ring  25 A, B may be positioned proximate the annular lip portion  29 A, B on the spud insert  26 A, B. A purpose of the annular lip portion  29 A, B may be to aid in positioning the threaded metal ring  25 A, B on the spud insert  26 A, B and to discourage removal of the threaded metal ring  25 A, B when the spud insert  26 A, B may be engaged with the top cover  21 , as will be discussed in greater detail later. Additionally, the spud insert  26 A, B may include a collar portion  28 A, B that may have a circumferential profile and may be positioned proximate to the lip portion  29 A, B. The collar portion  28 A, B may be shaped to engage a complementary shaped profile of the inner surface of the threaded metal ring  25 A, B to discourage relative rotation between the threaded metal ring  25 A, B and the spud insert  26 A, B. In one embodiment, the circumferential profile of the collar portion  28 A, B may define a shape having at least one linear section or facet. In other embodiments, the circumferential profile of the collar portion  28 A, B may define a shape having a plurality of linear sections. In such embodiments, the circumferential profile may take the shape of, for example, a triangle, square, pentagon, hexagon, or octagon. In even more embodiments, the circumferential profile of the collar portion  28 A, B may be substantially oval. In further embodiments, inner surface of the threaded metal ring  25 A, B may engage the collar portion  28 A, B by a key-fit arrangement. 
         [0025]    Extending from the collar  28 A, B of each spud insert  26 A, B may be an engagement portion  27 A, B. This engagement portion  27 A, B may have a cylindrical shape and may be sized to be positioned within the axial bore of a spud  23 A, B. The orifice proximate the engagement portion  27 A, B of each spud insert  26 A, B may be substantially circular in shape and may be substantially perpendicular to each cylindrically-shaped spud insert  26 A, B. In various embodiments, the exterior diameter of the engagement portion  27 A, B of each spud insert  26 A, B may be substantially similar to the interior diameter of the axial bore of each spud  23 A, B. Thus, the engagement portion  27 A, B of each spud insert  26 A, B fits snugly into its associated spud  23 A, B. In some embodiments, there may be a mild interference fit. The spud insert  26 A, B may be secured to the respective spud  23 A, B using spin welding, solvent welding, sonic welding, or an adhesive. An advantage of this arrangement may be that the metal threads do not contact the water supply and therefore do not impact the zero lead content requirements present in many jurisdiction. 
         [0026]    The threaded metal ring  25 A, B may be made from various types of metals and metal alloys, including brass, bronze, brass or bronze derivatives, stainless steel, or other similar metal materials. In a preferred embodiment, the threaded metal ring  25 A, B may be made of bronze. Factors that may be considered when selecting a material for the threaded metal ring  25 A, B include material strength and corrosion resistance. 
         [0027]    In alternative embodiments, the top cover  21  may include one spud or may include more than two spuds, in accordance with the present invention. In such embodiments, each spud would be similar in construction to the spuds disclosed above and would be shaped to engage a spud insert that may include a metal threaded ring, in accordance with the above disclosure. 
         [0028]    In various embodiments, the metering device  40  may be a nutating disk displacement flow meter, wobble plate meter, or other metering device known in the art. The metering device  40  may contain an inlet through which water enters the metering device  40  and an outlet through which water exits the metering device  40 . Referring to  FIG. 3 , the metering device  40  may contain a nutating disk  42  mounted on a sphere  44  that is “wobbled” by the fluid flow where each “wobble” represents a finite amount of fluid transferred. It should be understood that other types of metering devices may be used in connection with the present invention. 
         [0029]    The strainer  50  may be semi-cylindrical in shape and may be designed to be situated between the inlet spud of the top cover  21  and the inlet of the metering device  40 . The strainer  50  may be designed to strain foreign objects from the water before the water enters the metering device  40 . 
         [0030]    The metering device  40  and the strainer  50  may be positioned inside the top cover  21  and the bottom cover  60  may enclose them within the top cover  21 . The bottom cover  60  may be circular in shape and may contain a top face that may be configured to be positioned proximate to the top cover  21  and a bottom face that may be distal to the top cover  21 . The top face of the bottom cover  60  may contain a substantially annular channel that may be shaped and sized to engage the bottom end of the top cover  21 . In particular, the width of the channel may be substantially similar to thickness of the wall of the bottom end of the top cover  21 . The exterior wall of the channel may include threads that are configured to engage the external bottom threads  30  of the top cover  21  to enclose the metering device  40  and the strainer  50  within the interior cavity  31  of the top cover  21 . 
         [0031]    The bottom cover  60  may be made from various types of plastic or high-strength polymer materials, including styrene, polystyrene, nylon, or the like. In a preferred embodiment, the bottom cover  60  may be composed of glass reinforced thermoplastic. Factors that may be considered when selecting a material include working pressures of the meter, and working temperature ranges. 
         [0032]    The o-ring  55  may be positioned in the channel to provide a seal between the top cover  21  and the cover  60 . In the illustrated embodiment, the cross section of the o-ring is circular; however, other o-ring profiles may be used in connection with embodiments of the present invention. 
         [0033]    Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.