Cover system for an electrical-energy meter, and process for manufacture thereof

Abstract

A preferred process comprises providing a pre-formed, substantially transparent window for a cover of an electrical-energy meter, and molding the cover from a molten resin that, when solidified, is substantially opaque. Molding the cover from a molten resin comprises causing a portion of the molten resin to contact a periphery of the window and allowing the portion of the molten resin to cool and thereby solidify so that the portion of the molten resin, upon solidifying, is molded over the periphery of the window and thereby seals and secures the window to the cover.

1 - 19  Canceled  
     
     
         20 . An electrical-energy meter, comprising: 
 a base adapted to be mounted on a supporting surface;    a current sensor assembly comprising a plurality of contact blades extending through the base and adapted to electrically contact a conductor of electrical energy, and a current transformer mechanically coupled to the base and electrically coupled to the contact blades, the current transformer being adapted to produce an electrical output proportional to an electrical current in the conductor of electrical energy;    a circuit-board assembly comprising a main circuit board electrically coupled to the current transformer and the contact blades, the circuit-board assembly being adapted to calculate a cumulative amount of electrical energy passing through the conductor of electrical energy based on the electrical output of the current transformer and a voltage of the conductor of electrical energy; and    a cover system mounted on the base and comprising a substantially transparent window and a cover mechanically coupled to the base, wherein a portion of the cover is molded over a portion of the window.    
     
     
         21 . The electrical-energy meter of  claim 20 , wherein the cover has a cam surface formed thereon and the base has a complementary cam surface formed thereon and adapted to securely engage the cam surface on the cover.  
     
     
         22 . The electrical-energy meter of  claim 20 , wherein the cover is formed from a substantially opaque material.  
     
     
         23 . The electrical-energy meter of  claim 20 , wherein the cover comprises a side portion and a rim portion coupled to a first end of the side portion.  
     
     
         24 . The electrical-energy meter of  claim 23 , wherein the cover further comprises a face portion coupled to a second end of the side portion and at least partially molded over a portion of the window.  
     
     
         25 . The electrical-energy meter of  claim 24 , wherein the face portion has an edge defining a cutout in the face portion, and the edge is molded over the portion of the window.  
     
     
         26 . The electrical-energy meter of  claim 23 , wherein the cover further comprises a lip coupled to a second end of the side portion and the lip is molded over the portion of the window.  
     
     
         27 . The electrical-energy meter of  claim 20 , wherein the portion of the window is a peripheral edge of the window.  
     
     
         28 . The electrical-energy meter of  claim 20 , wherein the portion of the window has a recess formed on a first side thereon and a ridge formed on a second side thereof.  
     
     
         29 . The electrical-energy meter of  claim 20 , wherein the portion of the window is substantially curved.  
     
     
         30 . The electrical-energy meter of  claim 20 , wherein the window and the cover are formed from polycarbonate.  
     
     
         31 . A cover system for an electrical-energy meter, comprising: 
 a window formed from a substantially transparent material; and    a substantially cup-shaped cover comprising a circumferentially-extending side portion, a rim portion unitarily formed with a first end of the side portion and adapted to mate with a base of the electrical-power meter, and a lip extending from a second end of the side portion, wherein at least a portion of the lip is molded over a peripheral portion of the window.    
     
     
         32 . The cover system of  claim 31 , wherein the cover is substantially opaque.  
     
     
         33 . The cover system of  claim 31 , wherein the peripheral portion of the window is substantially curved to facilitate mechanical interlocking with the lip.  
     
     
         34 . The cover system of  claim 31 , wherein the window and the cover are formed from polycarbonate.  
     
     
         35 . The cover system of  claim 31 , wherein the window has a mold shutoff section formed thereon.  
     
     
         36 . The cover system of  claim 35 , wherein the mold shutoff section comprises a first substantially smooth surface portion located on a first surface of the window immediately inward of the peripheral portion of the window, and a second substantially smooth surface portion located on a second surface of the window immediately inward of the peripheral portion of the window.  
     
     
         37 . The cover system of  claim 31 , wherein the window has a pin-shaped projection formed thereon.  
     
     
         38 . A cover system for an electrical-energy meter, comprising: 
 a substantially transparent window; and    a substantially cup-shaped cover comprising a circumferentially-extending side portion, a rim portion unitarily formed with a first end of the side portion and adapted to mate with a base of the electrical-power meter, and a face portion adjoining a second end of the side portion, wherein the face portion has a cutout formed therein and adapted to receive the window, and at least a portion of the lip is molded over a peripheral portion of the window.    
     
     
         39 . The cover system of  claim 38 , wherein the window is substantially flat.  
     
     
         40 . The cover system of  claim 38 , wherein the window has a first and a second pin formed thereon.  
     
     
         41 . The cover system of  claim 38 , wherein the cover is substantially opaque.  
     
     
         42 . The cover system of  claim 38 , wherein the peripheral portion of the window has a ridge formed thereon and a trough formed therein to facilitate mechanical interlocking with the lip.  
     
     
         43 . The cover system of  claim 38 , wherein the window has a mold shutoff section formed thereon.  
     
     
         44 . The cover system of  claim 43 , wherein the mold shutoff section comprises a first substantially smooth surface portion located on a first surface of the window immediately inward of the peripheral portion of the window, and a second substantially smooth surface portion located on a second surface of the window immediately inward of the peripheral portion of the window.  
     
     
         45 . The cover system of  claim 38 , wherein the window and the cover are formed from polycarbonate.