ELECTROLYTE IN AN AREA OF DISSIMILAR METALS

CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority to U.S. Provisional Patent Application No.

62/716,487 filed August 9, 2018 and U.S. Provisional Patent Application No. 62/811,873 filed February 28, 2019, which are hereby incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

In the automotive wire harness industry, a typical header or device connector includes a seal for sealing against liquid (e.g., water) from leaking into an area housing wires and terminals.

However, in the automotive wire harness industry, when dissimilar metals are used, galvanic corrosion occurs in the presence of an electrolyte.

More particularly, dissimilar metals or alloys have different electrode potentials, and therefore when two or more dissimilar metals come into contact in an electrolyte, one acts as an anode and the other acts as a cathode. The presence of an electrolyte, which provides an electrical conducting path between dissimilar metals, causes galvanic corrosion to occur. As shown in FIG. 1, a contact area A1 located inside an area protected by a seal 10 is sealed from, for example, electrolyte and thus a, e.g., connector housing flange 15 made of a first type of metal and a, for example, housing or fixture 20 made of a second type of metal abutting and contacting or connected to each other is not subject to galvanic corrosion despite the first and second types of metal being dissimilar. However, a contact area A2 located outside the area protected by the seal 10 is subject to the entry of and unprotected from electrolyte, and is thus subject to galvanic corrosion. Also, the fastener or bolt 25 made of metal that is dissimilar from the type of metal that makes up the connector housing flange 15 includes a contact area A3 that is not protected from electrolyte and is thus subject to galvanic corrosion.

The fastener or bolt 25 includes a head 26; and a portion 27 below or beneath the head 26 is a washer 28 provided between the portion 27 below or beneath the head 26 and the housing or fixture 20.

If the washer 28 is made of a type of metal that is dissimilar from the type of metal that makes up the fastener or bolt head 26, the presence of electrolyte between the washer 28 and the fastener or bolt head 26 causes galvanic corrosion. Similarly, if the washer 28 is made of a type of metal that is dissimilar from the type of metal that makes up the housing or fixture 20, the presence of electrolyte between the washer 28 and the housing or fixture 20 causes galvanic corrosion.

The invention solves the problems inherent in the above-described typical header or device connector. This invention seals the fastener or bolt below the, e.g., bolt head (where the bolt 25 contacts dissimilar metals) from electrolyte (e.g., salt water or the like), thereby protecting the header or device connector from galvanic corrosion. SUMMARY OF THE INVENTION

This invention is directed to a sealing system and a method for sealing a metal fastener (e.g., a bolt or the like) and members having dissimilar metals for a header connector or a connector device from electrolyte (e.g., salt water or the like) in an area where, in the header connector or the connector device, certain dissimilar metals may be in contact. In this invention, the metal fastener (e.g., below a bolt head or the like) and other adjoining or abutting dissimilar metals are sealed by a non-conductive seal (preferably, a non-conductive silicone seal) of this invention from electrolyte, thereby protecting the metal fastener and the other adjoining or abutting dissimilar metals from galvanic corrosion and subsequently protecting the integrity of the header connector or the connector device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional elevational view of a known header or device connector in the automotive wire harness industry.

FIG. 2 is a cross-sectional elevational view' of an embodiment of a header or device connector of this invention showing a seal that protects fasteners, and abutting or adjoining members from electrolyte in areas of dissimilar metals. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIG. 2, a header or device connector 30 of this invention includes a member (e.g., a housing, a connector housing flange or the like) 35 having at least an aperture 38 passing therethrough. The member 35 may be made of a first type of metal or a stainless steel fiber-filled plastic or resin (e.g., EMI resin). Each aperture 38 accommodates therein a limiter 40, which may be made of a second type of metal, wherein the first type of metal of the member 35 may be a dissimilar type of metal from the second type of metal of the limiter 40. Passing through each limiter 40 is a fastener (e.g., a bolt or the like) 45. The fastener 45 is made of a third type of metal. The fastener 45 is preferably threaded to connect the member 35 having the first type of metal to a member (e.g., a metal housing or fixture, or the like) 50 having a fourth type of metal.

The first type of metal of the member 35, the second type of metal of the limiter 40, the third type of metal of the fastener 45, and the fourth type of metal of the member 50 may be made of any combination of dissimilar metals or may all be types of metal that are dissimilar from each other.

As further illustrated in FIG. 2, the member 50 made of the fourth type of metal has a side 53 that includes at least an indentation 55. Although the indentation 55 of the member 50 is shown in FIG. 2 as an elongated indentation, the indentation 55 may take any form (e.g., a plurality of elongated indentations, a single or multiple circular indentations, or the like) as long as the indentation 55 provides the necessary sealing between the side 53 of the member 50 and a side 36 of the adjoining member 35 having the first type of metal.

Presuming that the first type of metal of the member 35, the second type of metal of the limiter 40, the third type of metal of the fastener 45, and the fourth type of metal of the member 50 are all dissimilar from each other, galvanic corrosion can occur in area B 1 between threads 48 of the fastener 45 and the member 50, an area B2 between the limiter 40 and the member 50, an area B3 between the limiter 40 and the member 35, an area B4 between a body 47 of the fastener 45 and the limiter 40, and an area B5 between the limiter 40 and a portion 49 below _' or beneath a head 51 of the fastener 45 with the presence of electrolyte therebetween. Galvanic corrosion due to electrolyte is prevented in the above-described areas Bl, B2, B3, B4, and B5 with the employment of a seal 80 of this invention, as illustrated in FIG. 2 and as described in detail hereinafter.

The seal 80 of this invention is made of a non-conductive silicone, and includes a portion 82, which may be a single or a plurality of substantially flat portions located between the indentation (or a plurality of indentations) 55 of the member 50 and the member 35. The seal 80 further includes on opposing sides of the portion 82, at least a pad 84 that respectively sits into a corresponding groove 58 on opposing sides of the member 50. Covering each end 85 of the member 35 is a side cover portion 88 of the seal 80. The side cover portion 88 of the seal 80 is substantially C-shaped having ends 101, 102, the end 101 having at least a lower pad 84 of the seal 80, and the end 102 having at least an upper pad 90. The lower pad 84 and the upper pad 90 of the seal 80 are substantially opposite each other. The pad 90 of the seal 80 preferably sits inside a groove 105 located in the portion 49 below or beneath the head 51 of the fastener 45

The seal 80 further includes an extended portion 110, which includes an inner pad 93 that sits inside a groove 115 also located in the portion 49 below or beneath the head 51 of the fastener 45. Both the end 102 and the extended portion 110 of the seal 80 are located between the portion 49 below' or beneath the head 51 of the fastener 45 and the member 35.

As discussed above, the areas Bl, B2, B3, B4, and B5 are vulnerable to the presence of electrolyte in the absence of the seal 80 of this invention; and thus presuming the first type of metal (of the member 35), the second type of metal (of the limiter 40), the third type of metal (of the fastener 45), and the fourth type of metal (of the member 50) are all different from each other, the member 35, the limiter 40, the fastener 45, and the member 50 becomes susceptible to galvanic corrosion in the absence of the seal 80 of this invention.

The seal 80 of this invention protects the member 35, the limiter 40, the fastener 45, and the member 50 from galvanic corrosion by having the seal 80 of this invention prevent invasion of electrolyte into the above-discussed areas Bl, B2, B3, B4, and B5.

More particularly, each area B 1 (between the threads 48 of the fastener 45 and the member 50) is protected by at least one of the portion 82 of the seal 80 and a corresponding one of the pads 84 of the seal 80. Each area B2 (between the limiter 40 and the member 50) is protected by at least one of a corresponding one of the pads 84 of the seal 80, a corresponding one of the extended portions 110 of the seal 80, and a corresponding one of the pads 93 of the seal 80. Each area B3 (between the limiter 40 and the member 35) is protected by at least one of a corresponding one of the side cover portions 88 of the seal 80, a corresponding one of the pads 84, 90 of the seal 80, a corresponding one of the extended portions 110 of the seal 80, and a corresponding one of the pads 93 of the seal 80. Each area B4 (between the body 47 of the fastener 45 and the limiter 40) is also protected by at least one of a corresponding one of the side cover portions 88 of the seal 80, a corresponding one of the pads 84, 90 of the seal 80, a corresponding one of the extended portions 110 of the seal 80, and a corresponding one of the pads 93 of the seal 80. Each area B5 (between the limiter 40 and the portion 49 below or beneath the head 51 of the fastener 45) is protected by at least one of a corresponding one of the pads 90 of the seal 80, a corresponding one of the extended portions 110 of the seal 80, and a corresponding one of the pads 93 of the seal 80.

A method for sealing the metal fastener 45 from electrolyte in an area of dissimilar metals is hereinafter described. Each of the side cover portions 88 of the seal 80 wraps around and covers the respective end 85 of the member 35. The seal 80 is a non-conductive silicone seal or the like. The seal 80 has passing therethrough apertures for respectively accommodating therein the limiters 40. The member 35 with the seal 80 mounted or wrapped around thereof is then placed abutting the member 50 with the portion 82 of the seal 40 seated within the indentation 55 of the member 50. Each fastener 45 is inserted into a respective one of the limiters 40, and the threads 48 of each of the fasteners 45 are fastened into the member 50. Thereupon, each of the lower pads 84 of the seal 40 is respectively seated into a corresponding one of the grooves 58 of the member 50; each of the pads 90 of the seal 80 is respectively seated into a corresponding one of the grooves 105 located in the portion 49 below or beneath the head 51 of the fastener 45; and similarly, each of the pads 93 of the seal 80 is respectively seated into a corresponding one of the grooves 115 located in the portion 49 below or beneath the head 51 of the fastener 45

The present invention is not limited to the above-described embodiments; and various modifications in design, structural arrangement or the like may be used without departing from the scope or equivalents of the present invention.