WO2019152828A1 - Composite frost plate for water meter application - Google Patents

Abstract

The present disclosure relates to a composite frost plate adapted to engage with a water meter and formed of a discontinuous fiber reinforced matrix composite. The composite frost plate can include a first surface, a second surface opposing that of the first surface, a domed center portion sized and positioned to engage with an opening on a water vessel, and an outer portion configured for attachment to the water vessel. The outer portion can include a plurality of slotted bolting lugs, the outer portion formed to comprise at least one stiffener disposed at a periphery of the domed center portion. Where the second surface can be sized and positioned to be substantially flat at the outer portion to face the water vessel when the composite frost plate is coupled to the water vessel.

Description

COMPOSITE FROST PLATE FOR WATER METER APPLICATION

CROSS-REFERENCE TO RELATED APPLICATION

[001] This application claims the benefit of and priority to U.S. Provisional Application No. 62/625,500 entitled, “COMPOSITE FROST PLATE FOR WATER METER APPLICATION,” filed on February 2, 2018, the contents of which being incorporated by reference herein in its entirely.

BACKGROUND

[002] A municipal water meter is a unit for measuring water usage at residential homes, business, and industrial buildings. A frost plate is located at the bottom of the water meter and it is an essential part for protecting the water meter. Frost plates are designed to break to relieve the pressure inside the meter vessel and provide protection for the internal mechanism of the water meter at or below freezing temperatures.

SUMMARY OF THE INVENTION

[003] According to a first embodiment, a composite frost plate adapted to engage with a water meter formed of a discontinuous fiber reinforced matrix composite is described. The composite frost plate can include a first surface, a second surface opposing that of the first surface, a domed center portion sized and positioned to engage with an opening on a water vessel, and an outer portion configured for attachment to the water vessel. The outer portion can include a plurality of slotted bolting lugs and formed to include at least one stiffener disposed at a periphery of the domed center portion. The second surface can be sized and positioned to be substantially flat at the outer portion to face the water vessel when the composite frost plate is coupled to the water vessel.

[004] According to a second embodiment, a composite frost plate configured for use with a water meter is described. The composite frost plate can be formed of a composite material. The composite frost plate can include a domed center portion and an outer portion configured for attachment to a water vessel. The outer portion can include a plurality of slotted bolting lugs. The composite frost plate can have a first surface and a second surface on opposing surfaces of the composite frost plate. The second surface can be formed to be substantially flat at the outer portion.

[005] According to a third embodiment, a method of use of a composite frost plate is described comprising providing the composite frost plate of the first embodiment or second embodiment and attaching the composite frost plate to a water vessel.

[006] According to a fourth embodiment, a method of manufacturing a composite frost plate for use with a water meter is described, the method comprising providing pellets to form the a discontinuous fiber reinforced material, molding the discontinuous fiber reinforced material, wherein the molding is at least one of: extrusion compression molding, compression molding, injection molding, and injection compression molding, and forming the composite frost plate of the first embodiment or second embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

[007] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. [008] FIG. 1 illustrates an isometric view of a composite frost plate according to various embodiments of the present disclosure.

[009] FIG. 2 in an enlarged view of a slotted bolting lug portion of the composite frost plate according to various embodiments of the present disclosure.

[0010] FIG. 3 illustrates a top view of the composite frost plate according to various embodiments of the present disclosure.

[0011] FIG. 4 illustrates a side view of the composite frost plate according to various embodiments of the present disclosure.

[0012] FIGS. 5A and 5B illustrate bottom views of the composite frost plate according to various embodiments of the present disclosure.

[0013] FIG. 6 illustrates the placement of the composite frost plate on the corresponding surface of an opening on a water meter vessel showing an exploded view according to various embodiments of the present disclosure.

[0014] FIG. 7A illustrates the extrusion compression molding process for fabricating the composite frost plate using fiber reinforced polymer pellets according to various embodiments of the present disclosure.

[0015] FIG. 7B illustrates an example of the size of discontinuous glass fiber reinforced polypropylene pellets that can be used in the extrusion compression molding process illustrated in FIG. 7 according to various embodiments of the present disclosure.

DETAILED DESCRIPTION

[0016] The present disclosure relates to a composite frost plate for a water meter, also referred to as a composite frost plate or a water meter frost plate formed of a composite material. A frost plate is located at the bottom of a water meter and is an essential part for protecting the water meter. For example, a municipal water meter is an apparatus that measures water usage at residential homes, businesses, and industrial buildings. Frost plates are designed to intentionally break to relieve the pressure inside the meter vessel and provide protection for the internal mechanism of the water meter at or below freezing temperatures. When water freezes, its volume increases. The increased volume of water can induce large amounts of internal stress inside a closed water meter vessel. If the pressure is not relieved, the water meter vessel or its internal mechanism could break which can be expensive to replace. Flowever, by sacrificing the frost plate, the damage to the meter can be avoided and only the frost plate needs to be replaced.

[0017] Currently, bronze and cast iron are the most common materials for existing frost plates. Flowever, the use of bronze is declining as a frost plate material due to the material costs as well as the costs for processing bronze. Moreover, bronze normally contains lead that could leach into the water supply severely contaminate the running water. For example, a study in Flint, Michigan determined that the water contamination that sickened people, including children, was attributed to lead leached into the running water. While cast iron is generally safer and has a lower cost, it tends to corrode and can lose its function when exposed to the underground moisture and/or other corrosive mediums for a limited time. The reduced strength of cast iron caused by the corrosion could lead to premature failure of the frost plate and result in sudden water burst during normal operation.

[0018] The composite frost plate described herein addresses the aforementioned problems of with existing frost plates by providing a discontinuous fiber reinforced polymer matrix composite frost plate that provides strength, corrosion resistance, as well as resistance to fatigue caused by repeated freeze-thaw cycles at an equivalent or reduced cost compared to bronze frost plates and similar frost plates. The combination of material selection and the geometric design of the composite frost plate provides a solution capable of withstanding the running water pressure imposed during normal operation; however, the composite frost plate can break when the water freezes and internal pressure climbs.

[0019] According to various embodiments, a composite frost plate may be formed of discontinuous fiber reinforced composite materials having a strength suitable to withstand water pressure that results in a max stress on the composite frost plate ranging from about 40 MPa to about 400 MPa. As will become appreciated, a composite material with high strength characteristics can be employed in a thinner geometry while meeting pressure requirements for frost plates, whereas composite materials having a lower strength can be employed using a thicker geometry. A discontinuous fiber reinforced composite can be molded to achieve the desired complex geometry of the composite frost plate described herein. The composite frost plate described herein also provides excellent corrosion resistance.

[0020] The composite frost plate described herein provides a cover for a water vessel shaped and sized to connect with existing water vessels. The size of the composite frost plate can be configured to match the diameter of the water meter, which can range from about 5/8 inch to about 12 inches. Accordingly, the diameter of the composite frost plate can range from about 5/8 inch to about 12 inches, or be include an additional tolerance to ensure the aperture of the water vessel is covered.

[0021] According to various embodiments of the present disclosure, bolting lugs can be slotted and arranged tangentially to an outer circumference of the composite frost plate such that, when the composite frost plate is placed on the meter and twisted, the bolting lugs engage bolts on a meter and secure the composite frost plate to the meter. Therefore, the composite frost plate can be replaced without removing the bolts and is detachably attachable to the meter. Stiffeners are also added to the periphery of the composite frost plate to maintain adequate stiffness for sealing purpose as the composite material has a lower elastic modulus than a brass or cast iron frost plate. The stiffener can be formed as a part of the composite frost plate and molded in one piece with the composite frost plate in a single step with the same material. In various embodiments, no extra processing step or additional material are required to mold the stiffener, as can be appreciated. The stiffener can also function as a rib that provides geometrical stiffness.

[0022] Turning now to FIG. 1 , a composite frost plate 100 is illustrated having a first face 103 and a second face 106 on opposing surfaces of the composite frost plate 100. The composite frost plate 100 may include a center portion 109 that, in some embodiments, is substantially circular and has a thickness and a domed curvature. Additionally, the center portion 109 may be convex on the first face 103 and concave on the second face 106 in some embodiments. An outer portion 1 12 of the composite frost plate 100 may surround the center portion 109 and can include a shoulder 142 that tapers to a plate thickness (T) to anchor the composite frost plate 100 at the bolting lugs 1 15 to a water vessel (not shown). The outer portion 1 12 of the composite frost plate 100 may also include stiffeners in some embodiments.

[0023] In the example shown in FIG. 1 , four stiffeners 1 18a...1 18d (collectively “stiffeners 1 18”), or other suitable number of stiffeners, may be interposed between four bolting lugs 1 15a...1 15d (collectively“bolting lugs 1 15”), as shown. The stiffeners 1 18 can be arcuate in shape to match the curvature at the circumference of the center portion and shoulder 142. The stiffeners 1 18 can include a thickness substantially greater than the thickness at bolting lug 1 15 portion being flat on the second face 106, thereby providing a substantially flat portion at the outer portion 112 on the second face 106 that ensures a tight connection with the corresponding connection plate of a water vessel. In some embodiments, the stiffeners 118 can include projections positioned on a distal end of the outer portion 112 that extend perpendicular to the substantially flat portion at the outer portion 112 on the second face 106. In the example shown in FIG. 1 , there are four bolting lugs 115 spaced evenly about and arranged tangentially to the outer circumference of the center portion 109. It is understood that a plurality of bolting lugs 115 can be arranged to correspond with the positioning of corresponding bolts on a water vessel (not shown).

[0024] Next, FIG. 2 shows an enlarged view of callout region 2 shown in FIG. 1 , representing of one of the bolting lugs 115 from the composite frost plate 100. The bolting lug 115 may be substantially plate-like and have an appreciable thickness. Further, the bolting lug 115 may be substantially flat on both the first face 103 and second face 106. The bolting lug 115 may extend or project radially outward from the center portion 109 of the composite frost plate 100 while having a curved shape.

[0025] The bolting lug 115 may be configured with a bolt seat 121 centered along a radial line (R) to at least partially surround and a hold a bolt to connect a water vessel. The bolt seat 121 can also include an arcuate portion 145 shaped in the shoulder 142 extending the flat portion on the first face 103 to accommodate the head of a bolt when the composite frost plate 100 is secured to the water vessel. In other words, the bolting seat 121 can engage with a bolt of a water vessel to form an interference fit.

[0026] A slot 124 extends from the bolt seat 121 to an edge 127 of the bolting lug 115, where the slot 121 is substantially parallel to a tangent of the circumference of the center portion 109. The width of the slot 124 tapers from a seat width 130 to have an edge width 133 that is wider at the edge 127 of the bolting lug 1 15.

[0027] Turning now to FIG. 3, a top view of the composite frost plate 100 is shown. The slots 124a...124d (collectively“slots 124”) of the bolting lug 1 15 are arranged tangentially to the outer circumference such that when the composite frost plate is placed on the meter and twisted it engages the bolts; therefore, the composite frost plate 100 can be replaced without removing bolts installed on a meter. In the example shown in FIG. 3, there are four bolting lugs 1 15 spaced evenly about and arranged tangentially to the outer circumference of the center portion 109 with four stiffeners 1 18 arranged among the bolting lugs 1 15 in a symmetrical alternating pattern tangential to the outer circumference of the center portion 109. The bolting lugs 1 15 are positioned with each open edge of a slot 124 is on the same side of each respective bolting lug 1 15 forming a pinwheel pattern about the center portion 109. Each of the slots 124 faces a tangential direction such that the composite frost plate 100 can be secured to a water vessel by aligning the edge width 133 of each slot 124 with a corresponding bolt on a meter, then rotating the composite frost plate 100 clockwise to engage a bolt in each bolt seat 121 .

[0028] Next in FIG. 4, a side view of a composite frost plate 100 is shown. The center portion 109 may include a domed profile shown in relation to the outer portion 1 12 having a thickness (T) of the bolting lugs 1 15 and stiffeners 1 18. The convex shape of the first face 103 of the center portion 109 and the concave shape of the second face 106 of the center portion 109 are also shown.

[0029] The outer portion 1 12 of the second face 106 may be substantially flat to secure to a plate of a water vessel. The domed center portion 109 can include a height 133 measured with from the base of the composite frost plate 100 at the substantially flat second surface 106 to the top of the domed center portion 109 at the first surface 103. Each of the stiffeners 1 18 can include a height 136 measured with from the base of the composite frost plate 100 at the substantially flat second surface 106 to the top of stiffener 1 18 at the first surface 103.

[0030] In some embodiments, the height of the stiffener 136 can be the same as or substantially similar to the height 139 of the domed center portion 109. Also, in some embodiments, the height of the stiffener 136 can be the greater or less than the height 139 of the domed center portion 109. The composite frost plate 100 can include a step 148 at the mating surface that can be pushed against a gasket (not shown) in a water meter that provides a seal to prevent any water leakage. The step is on the second face 106 of the outer portion 1 12.

[0031] Referring next to FIGS. 5A and 5B, the second face 106 of the composite frost plate is shown according to various embodiments. The second face 106 can be concave to substantially correspond with the domed center portion 109. The center portion 109 can include a hub section 151 at the center of the center portion which maintains the concave curvature or is flat. The outer portion 1 12 can include the step 148, which is substantially ring-shaped and having a radial width and a thickness that protrudes from a substantially flat rim 154 that is continuously meeting the substantially flat second face of the bolting lugs 1 15. The step 148 can be position on the second face 106 of the outer portion 1 12. A gasket (not shown) can be disposed to abut the step 148, so that the gasket is disposed between the rim 154 and the water vessel (not shown).

[0032] Turning to FIG. 6, shown is an example of an assembly of the composite frost plate 100 with a corresponding water vessel 200. The water vessel 200 has a surface 203 around an opening 206 providing a substantially flat surface to mount the composite frost plate 100. The water meter vessel 200 can have a bolt portion 209 with a flat surface and a thickness that protrude radially from the circumference of the opening 206 of the water vessel 200.

[0033] The bolt portion 209 has a bolt hole 212 along a radial centerline that is configured to receive a bolt (not shown). The composite frost plate 100 is configured to have a center portion 109 that may be sized to correspond with opening 206 on a water vessel 200. The outer portion 1 12 of the composite frost plate 100 may be configured and sized to correspond with the water vessel rim surface 203 around the opening 206. The bolting lugs 1 15 of the composite frost plate 100 may be configured to correspond in position with the bolt portion 209, such that, the bolt holes 212 are in line with the bolt seat 121 to provide a passage for a bolt to secure the composite frost plate 100 to a water vessel 200.

[0034] It is understood that the example shown FIG. 6 is only one possible configuration due to the number of existing water vessels. The composite frost plate 100 can be configured to correspond to a variety of water vessels, as can be appreciated. A gasket (not shown) can be disposed to abut the step 148, so that the gasket is disposed between the rim 154 and surface 203 when the composite frost plate 100 is attached to the water vessel 200.

[0035] Next, FIG. 7A illustrates an extrusion compression molding process for fabrication of the composite frost plate 100 using pellets 700 comprising a thermoplastic polymer and reinforcing fiber. For example, pellets 700 comprising discontinuous glass fiber reinforced polypropylene composite material (Glass/PP) can be used for the manufacturing the composite frost plate 100 are shown in FIG. 7B with a penny for size reference. In some embodiments, a pellet 700 length can be in a range from about 2 mm to about 25 mm. Notably, longer pellets 700 normally result in longer fibers. The processing for longer pellets 700 is more difficult; however, more suitable material properties can be achieved.

[0036] Pellets 700 can include a thermoplastic polymer and reinforcing fiber, as can be appreciated. The amount of thermoplastic polymer can be about 50 to 99 weight % of the discontinuous fiber composite material and the amount of reinforcing fiber can be about 0.1 to 50 weight % of the composite material. Example thermoplastic polymers include polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, or combinations thereof. Example reinforcing fibers include carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, or combinations thereof.

[0037] In accordance with various embodiments, the composite frost plate 100 can be formed through molding processes such as compression molding, injection molding process, injection compression molding process, or a combination thereof. Each molding process can begin with pellets 700 comprising thermoplastic polymer and reinforcing fiber. A suitable processing temperature can be determined depending on a type of the thermoplastic polymer in the composite material. The processing temperature of lower melting temperature polymers, such as polyethylene, can be as low as about 140°C, whereas the processing temperature of poly ether ether ketone (PEEK) can be as high as about 360°C. Additionally, a draft angle ranging from about 0.5 degrees to about 4 degrees can be added to the vertical surfaces to ensure easy demolding of the composite frost plate during molding. Table 1 , below, shows examples of material properties for an embodiment of a composite frost plate:

Table 1 : Example Properties for a Composite Frost Plate

[0038] Specifically, Table 1 lists the material properties for discontinuous glass fiber reinforced polypropylene composite material (glass/PP) that used as the material for the composite frost plate. The material properties provide for the stress condition of a composite frost plate.

[0039] Consistent with the embodiments described herein, a stress analysis was performed using the composite frost plate 100 such that the composite frost plate 100 fails before the brass vessel or the internal mechanism of the water meter fails when water freezes. The tensile strength, compressive strength, and the strain to failure are the parameters that define the failure of the composite frost plate 100. The composite frost plate 100 can be formed to have adequate strength to withstand the water pressure during normal operation. The adequate strength is defined when the stress caused by the pressurized water is lower than the strength of the composite material. The pressure at normal operation is about 30 to about 60 psi.

[0040] Although the properties of discontinuous glass fiber reinforced polypropylene composite material (glass/PP) is shown as one example, other discontinuous fiber reinforced polymer matrix composites can be considered. As described above, the discontinuous fiber reinforced polymer matrix composite can comprise a thermoplastic polymer selected from the group consisting of polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, and combinations thereof. As described above, the discontinuous fiber reinforced polymer matrix composite can comprise reinforcing fiber selected from the group consisting of carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, and combinations thereof.

[0041] Disjunctive language such as the phrase“at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.

[0042] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims and clauses.

[0043] Clause 1 . A composite frost plate adapted to engage with a water meter formed of a discontinuous fiber reinforced matrix composite, the composite frost plate comprising: a first surface; a second surface opposing that of the first surface; a domed center portion sized and positioned to engage with an opening on a water vessel; and an outer portion configured for attachment to the water vessel, the outer portion comprising a plurality of slotted bolting lugs, the outer portion formed to comprise at least one stiffener disposed at a periphery of the domed center portion; wherein the second surface is sized and positioned to be substantially flat at the outer portion to face the water vessel when the composite frost plate is coupled to the water vessel.

[0044] Clause 2. The composite frost plate of clause 1 , wherein the discontinuous fiber reinforced matrix composite comprises: a thermoplastic polymer ranging from about 50 to 99 weight % of the a discontinuous fiber reinforced matrix composite; and fiber reinforcements ranging from about 0.1 to 50 weight % of the a discontinuous fiber reinforced matrix composite.

[0045] Clause 3. The composite frost plate of clause 1 or 2, wherein the thermoplastic polymer is selected from the group consisting of polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, and combinations thereof.

[0046] Clause 4. The composite frost plate of any of clauses 1 -3, wherein the fiber reinforcements are selected from the group consisting of carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, and combinations thereof.

[0047] Clause 5. A composite frost plate configured for use with a water meter, the composite frost plate formed of a composite material, the composite frost plate comprising: a domed center portion; and an outer portion configured for attachment to a water vessel, the outer portion comprising a plurality of slotted bolting lugs;

wherein the composite frost plate has a first surface and a second surface on opposing surfaces of the frost plate, the second surface configured to be

substantially flat at the outer portion.

[0048] Clause 6. The composite frost plate of clause 5, wherein the outer portion is formed to include at least one stiffener.

[0049] Clause 7. The composite frost plate of clauses 5 and 6 wherein the domed center portion has a thickness of the composite material between the first surface and the second surface, the thickness having at least one portion configured to rupture in response to a pressure greater than a predefined pressure being applied to the second surface of the domed center portion.

[0050] Clause 8. The composite frost plate of any of clauses 5-7, wherein the domed center portion is sized and configured to correspond with an opening on the water vessel.

[0051] Clause 9. The composite frost plate of any of clauses 5-8, further comprising an annular step in the second surface at a rim, the annular step configured to mate with the opening of the water vessel and a gasket to prevent leakage.

[0052] Clause 10. The composite frost plate of any of clauses 5-9, wherein the shape of the periphery of the domed center portion is substantially circular having an inner circumference on the second surface, wherein the inner circumference is substantially the same as a circumference of the opening on the water vessel.

[0053] Clause 1 1 . The composite frost plate of any of clauses 5-10, wherein each slotted bolting lug of the plurality of slotted bolting lugs comprises: a bolt seat configured to receive a bolt to secure the composite frost plate to the water vessel; and a slot having an opening width greater than a seat width, the seat width being measured at the bolt seat.

[0054] Clause 12. The composite frost plate of any of clauses 5-1 1 , wherein the composite material is a discontinuous fiber reinforced polymer matrix composite material comprising a thermoplastic polymer and fiber reinforcements.

[0055] Clause 13. The composite frost plate of any of clauses 5-12, wherein the thermoplastic polymer is selected from the group consisting of polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, and combinations thereof.

[0056] Clause 14. The composite frost plate of any of clauses 5-13, wherein the fiber reinforcements are selected from the group consisting of carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, and combinations thereof.

[0057] Clause 15. The composite frost plate of any of clauses 5-14, wherein the composite material is a discontinuous glass fiber reinforced polypropylene composite material.

[0058] Clause 16. The frost plate of any of clauses 5-14, wherein the thermoplastic polymer is polypropylene and the fiber reinforcements are glass.

[0059] Clause 17. The composite frost plate of any of clauses 5-16, wherein the composite is formed by a molding process, wherein the molding process is extrusion compression molding, compression molding, injection molding, or injection compression molding. [0060] Clause 18. The composite frost plate of any of clauses 5-17, wherein material properties of the composite material define failure of the frost plate, the material properties comprising tensile strength, compressive strength, and strain to failure.

[0061] Clause 19. The composite frost plate of any of clauses 5-18, wherein the frost plate is formed to withstand water pressure causing stress on the frost plate, the composite material of the frost plate having a strength ranging from about 40 MPa to about 400 MPa.

[0062] Clause 20. The composite frost plate of any of clauses 5-19, wherein the at least one stiffener is a plurality of stiffeners disposed at a periphery of the domed center portion spaced evenly and interposed between the plurality of slotted bolting lugs.

[0063] Clause 21 . A method of use of a composite frost plate comprising: providing the composite frost plate of any of clauses 1 -20; and attaching the composite frost plate to a water vessel.

[0064] Clause 22. A method of manufacturing a composite frost plate for use with a water meter, the method comprising: providing pellets to form the a discontinuous fiber reinforced material; molding the discontinuous fiber reinforced material, wherein the molding is at least one of: extrusion compression molding, compression molding, injection molding, and injection compression molding; and forming the composite frost plate of any of clauses 1 -20.

[0065] Clause 23. The method of clause 22, wherein the pellets have a length of about 2mm to about 25 mm.

[0066] Clause 24. The method of clause 22 or 23, wherein the molding is performed at a processing temperature between about 140°C to about 360°C. [0067] Clause 25. The method of any of clauses 22-24, wherein at least one stiffener is formed as part of the composite frost plate and molded in one step with the same discontinuous fiber reinforced material forming the composite frost plate in one piece.

Claims

CLAIMS Therefore, the following is claimed:

1. A composite frost plate adapted to engage with a water meter formed of a discontinuous fiber reinforced matrix composite, the composite frost plate comprising:

a first surface;

a second surface opposing that of the first surface;

a domed center portion sized and positioned to engage with an opening on a water vessel; and

an outer portion configured for attachment to the water vessel, the outer portion comprising a plurality of slotted bolting lugs, the outer portion formed to comprise at least one stiffener disposed at a periphery of the domed center portion;

wherein the second surface is sized and positioned to be substantially flat at the outer portion to face the water vessel when the composite frost plate is coupled to the water vessel.

2. The composite frost plate of claim 1 , wherein the discontinuous fiber reinforced matrix composite comprises: a thermoplastic polymer ranging from about 50 to 99 weight % of the a discontinuous fiber reinforced matrix composite; and fiber reinforcements ranging from about 0.1 to 50 weight % of the a discontinuous fiber reinforced matrix composite.

3. The composite frost plate of claim 2, wherein:

the thermoplastic polymer is selected from the group consisting of polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, and combinations thereof; and

the fiber reinforcements are selected from the group consisting of carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, and combinations thereof.

4. A composite frost plate configured for use with a water meter, the composite frost plate formed of a composite material, the composite frost plate comprising:

a domed center portion; and

an outer portion configured for attachment to a water vessel, the outer portion comprising a plurality of slotted bolting lugs;

wherein the composite frost plate has a first surface and a second surface on opposing surfaces of the composite frost plate, the second surface configured to be substantially flat at the outer portion.

5. The composite frost plate of claim 4, wherein the outer portion is formed to include at least one stiffener.

6. The composite frost plate of claim 4, wherein the domed center portion has a thickness of the composite material between the first surface and the second surface, the thickness having at least one portion configured to rupture in response to a pressure greater than a predefined pressure being applied to the second surface of the domed center portion.

7. The composite frost plate of claim 4, wherein the domed center portion is sized and configured to correspond with an opening on the water vessel.

8. The composite frost plate of claim 7, further comprising an annular step in the second surface at a rim, the annular step configured to mate with the opening of the water vessel and a gasket to prevent leakage.

9. The composite frost plate of claim 7, wherein the shape of the periphery of the domed center portion is substantially circular having an inner circumference on the second surface, wherein the inner circumference is substantially the same as a circumference of the opening on the water vessel.

10. The composite frost plate of claim 4, wherein each slotted bolting lug of the plurality of slotted bolting lugs comprises:

a bolt seat configured to receive a bolt to secure the composite frost plate to the water vessel; and

a slot having an opening width greater than a seat width, the seat width being measured at the bolt seat.

11. The composite frost plate of claim 4, wherein the composite material is a discontinuous fiber reinforced polymer matrix composite material comprising a thermoplastic polymer and fiber reinforcements.

12. The composite frost plate of claim 11 , wherein the thermoplastic polymer is selected from the group consisting of polyamide, acrylonitrile butadiene styrene (ABS), polyphenylene sulfide, polyethersulfone, polypropylene, polycarbonate, polyphenylene sulfide, poly ether ether ketone (PEEK), poly ether ketone (PEK), polyethylene, poly butylene terephthalate, poly ethylene terephthalate, polyoxymethylene, and combinations thereof.

13. The composite frost plate of claim 11 , wherein the fiber reinforcements are selected from the group consisting of carbon, glass, aramid, polypropylene, polyethylene, basalt, poly{diimidazo pyridinylene (dihydroxy) phenylene}, and combinations thereof.

14. The composite frost plate of claim 4, wherein the composite material is a discontinuous glass fiber reinforced polypropylene composite material.

15. The composite frost plate of claim 4, wherein the composite is formed by a molding process, wherein the molding process is extrusion compression molding, compression molding, injection molding, or injection compression molding.

16. A method of use of a composite frost plate comprising:

providing the composite frost plate of claim 1 ; and

attaching the composite frost plate to a water vessel.

17. A method of manufacturing a composite frost plate for use with a water meter, the method comprising:

providing pellets to form the a discontinuous fiber reinforced material; molding the discontinuous fiber reinforced material, wherein the molding is at least one of: extrusion compression molding, compression molding, injection molding, and injection compression molding; and

forming the composite frost plate of claim 1.

18. The method of claim 17, wherein the pellets have a length of about 2mm to about 25 mm.

19. The method of claim 17, wherein the molding is performed at a processing temperature between about 140°C to about 360°C.

20. The method of claim 17, wherein at least one stiffener is formed as part of the composite frost plate and molded in one step with the same discontinuous fiber reinforced material forming the composite frost plate in one piece.