System and method for sealing metal fastener from electrolyte in area of dissimilar metals

Abstract

To provide a sealing system and a method for sealing a metal fastener and members having dissimilar metals for a header connector or a connector device from electrolyte in an area where, in the header connector or the connector device, certain dissimilar metals may be in contact.SOLUTION: A metal fastener 45 and other adjoining or abutting dissimilar metals are sealed with a non-conductive seal 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.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] 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 by reference in their entireties. [Background technology]

[0002] In the automotive wire harness industry, a typical header or device connector includes seals to prevent liquids (e.g., water) from leaking into the area that contains the wires and terminals. However, when dissimilar metals are used in the automotive wire harness industry, galvanic corrosion occurs in the presence of electrolytes.

[0003] More specifically, 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 as a cathode. The presence of an electrolyte that provides a conductive path between dissimilar metals causes galvanic corrosion to occur. As shown in FIG. 1, the contact area A1 located within the area protected by the seal 10 is sealed from the electrolyte, for example, and therefore the connector housing flange 15, made from a first type of metal, and the housing or fastener 20, made from a second type of metal that abuts and contacts or connects with each other, for example, are not subject to galvanic corrosion, even though the first type of metal and the second type of metal are dissimilar. However, the contact area A2 located outside the area protected by the seal 10 is penetrated by the electrolyte, is not protected from the electrolyte, and is therefore subject to galvanic corrosion. Also, the fastener or bolt 25, made from a metal that is dissimilar to the type of metal that constitutes the connector housing flange 15, includes a contact area A3 that is not protected from the electrolyte, and is therefore subject to galvanic corrosion.

[0004] Fastener or bolt 25 includes a head 26 ; below or just below portion 27 of head 26 is a washer 28 disposed between the below or just below portion 27 of head 26 and housing or fixture 20 .

[0005] If the washer 28 is made from a different type of metal than the type of metal that makes up the fastener or bolt head 26, the presence of an electrolyte between the washer 28 and the fastener or bolt head 26 will cause galvanic corrosion. Similarly, if the washer 28 is made from a different type of metal than the type of metal that makes up the housing or fastener 20, the presence of an electrolyte between the washer 28 and the housing or fastener 20 will cause galvanic corrosion.

[0006] The present invention solves the problems inherent in the typical header or device connector described above by, for example, sealing the fastener or bolt below the bolt head (where the bolt 25 contacts the dissimilar metal) from the electrolyte (e.g., salt water, etc.), thereby protecting the header or device connector from galvanic corrosion. Summary of the Invention [Means for solving the problem]

[0007] The present invention relates to a sealing system and method for sealing metallic fasteners (e.g., bolts, etc.) and components having dissimilar metals of a header connector or connector device from an electrolyte (e.g., salt water, etc.) in areas where certain dissimilar metals may come into contact in the header connector or connector device, in which the metallic fasteners (e.g., below the bolt heads, etc.) and other adjacent or abutting dissimilar metals are sealed from the electrolyte by a non-conductive seal (preferably a non-conductive silicone seal) of the present invention, thereby protecting the metallic fasteners and other adjacent or abutting dissimilar metals from galvanic corrosion and subsequently protecting the integrity of the header connector or connector device. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view of a known header or device connector in the automotive wiring harness industry. [Diagram 2] FIG. 2 is a cross-sectional view of one embodiment of a header or device connector of the present invention showing fasteners and seals that protect abutting or adjacent components from electrolytes in areas of dissimilar metals. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] As shown in FIG. 2, the header or device connector 30 of the present invention includes a member (e.g., a housing, connector housing flange, etc.) 35 having at least an aperture 38 therethrough. The member 35 can be made of a first type of metal or a stainless steel fiber-filled plastic or resin (e.g., an EMI resin). Each aperture 38 houses a limiter 40 therein, which can be made of a second type of metal, where the first type of metal of the member 35 can be a different type of metal than the second type of metal of the limiter 40. Passing through each limiter 40 is a fastener (e.g., a bolt, etc.) 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, etc.) 50 having a fourth type of metal.

[0010] The first type of metal member 35, the second type of metal limiter 40, the third type of metal fastener 45, and the fourth type of metal member 50 may be made from any combination of dissimilar metals or may all be of different types of metals.

[0011] As further shown in Figure 2, member 50 made from the fourth type of metal has a side 53 that includes at least a recess 55. Although recess 55 of member 50 is shown in Figure 2 as an elongated recess, recess 55 can take any form (e.g., multiple elongated recesses, single or multiple circular recesses, etc.) so long as it provides the requisite seal between side 53 of member 50 and side 36 of adjacent member 35 having the first type of metal.

[0012] Assuming that the first type metal of member 35, the second type metal of limiter 40, the third type metal of fastener 45, and the fourth type metal of member 50 are all dissimilar to one another, galvanic corrosion can occur in area B1 between threads 48 of fastener 45 and member 50, area B2 between limiter 40 and member 50, area B3 between limiter 40 and member 35, area B4 between body 47 of fastener 45 and limiter 40, and area B5 between limiter 40 and portion 49 below or beneath head 51 of fastener 45 due to the presence of electrolyte therebetween. Galvanic corrosion caused by electrolyte is prevented in areas B1, B2, B3, B4, and B5 by employing seal 80 of the present invention as shown in FIG. 2 and described in detail below.

[0013] The seal 80 of the present invention is made of non-conductive silicone and includes a portion 82, which may be a single or multiple generally flat portions positioned between the recess (or recesses) 55 of the member 50 and the member 35. The seal 80 further includes at least pads 84 on either side of the portion 82 that fit into corresponding grooves 58 on either side 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 generally C-shaped having ends 101, 102, with the end 101 having at least the lower pad 84 of the seal 80 and the end 102 having at least the upper pad 90. The lower pad 84 and the upper pad 90 of the seal 80 are generally opposite each other. The pad 90 of the seal 80 fits into a groove 105 that is preferably positioned in the portion 49 below or just below the head 51 of the fastener 45.

[0014] Seal 80 further includes an extension portion 110, which includes an inner pad 93 recessed within a groove 115 that is also positioned in portion 49 below or beneath head 51 of fastener 45. Both end 102 and extension portion 110 of seal 80 are positioned between portion 49 below or beneath head 51 of fastener 45 and member 35.

[0015] As explained above, areas B1, B2, B3, B4 and B5 are susceptible to the presence of electrolyte in the absence of seal 80 of the present invention; therefore, assuming that the first type of metal (of member 35), the second type of metal (of limiter 40), the third type of metal (of fastener 45) and the fourth type of metal (of member 50) are all dissimilar to one another, member 35, limiter 40, fastener 45 and member 50 are susceptible to galvanic corrosion in the absence of seal 80 of the present invention.

[0016] The seal 80 of the present invention protects the member 35, the limiter 40, the fastener 45 and the member 50 from galvanic corrosion by preventing the electrolyte from entering the areas B1, B2, B3, B4 and B5 described above through the seal 80 of the present invention.

[0017] More specifically, each area B1 (between threads 48 of fastener 45 and member 50) is protected by at least one of portion 82 of seal 80 and a corresponding one of pads 84 of seal 80. Each area B2 (between limiter 40 and member 50) is protected by at least one of a corresponding one of pads 84 of seal 80, a corresponding one of extension portions 110 of seal 80, and a corresponding one of pads 93 of seal 80. Each area B3 (between limiter 40 and member 35) is protected by at least one of a corresponding one of side cover portion 88 of seal 80, a corresponding one of pads 84, 90 of seal 80, a corresponding one of extension portions 110 of seal 80, and a corresponding one of pads 93 of seal 80. Each area B4 (between body 47 of fastener 45 and limiter 40) is similarly protected by at least one of a corresponding one of side cover portions 88 of seal 80, a corresponding one of pads 84, 90 of seal 80, a corresponding one of extension portions 110 of seal 80, and a corresponding one of pads 93 of seal 80. Each area B5 (between limiter 40 and portion 49 below or just below head 51 of fastener 45) is protected by at least one of a corresponding one of pads 90 of seal 80, a corresponding one of extension portions 110 of seal 80, and a corresponding one of pads 93 of seal 80.

[0018] A method of sealing the metal fasteners 45 from the electrolyte in areas of dissimilar metals is described below. Each of the side cover portions 88 of the seal 80 wraps around and covers a respective end 85 of the member 35. The seals 80 are non-conductive silicone seals or the like. The seals 80 have openings therethrough that each accommodate a limiter 40 therein. The member 35 with the seal 80 attached or wrapped therearound is then placed against the member 50 with the portion 82 of the seal 40 seated within the recess 55 of the member 50. Each of the fasteners 45 is inserted into a respective one of the limiters 40 and the respective threads 48 of the fastener 45 are tightened into the member 50.

[0019] Then, each of the lower pads 84 of the seal 40 is seated in a corresponding one of the grooves 58 of the member 50; each of the pads 90 of the seal 80 is seated in a corresponding one of the grooves 105 located in the portion 49 below or directly below the head 51 of the fastener 45; and similarly, each of the pads 93 of the seal 80 is seated in a corresponding one of the grooves 115 located in the portion 49 below or directly below the head 51 of the fastener 45.

[0020] The present invention is not limited to the above-described embodiments; various modifications in design, structural arrangements, and the like can be used without departing from the scope or equivalent of the present invention.

Claims

1. The present invention features a seal, the seal comprising: at least a generally planar portion seated between the first member and the second member; and end portions on either side of the generally planar portion, each of the end portions being generally C-shaped and each attached to an end portion of the first member, each of the generally C-shaped end portions of the seal having a lower end portion and an upper end portion, each lower end portion having at least a lower pad and each upper end portion having at least an upper pad; an extension portion extending from the upper end portion and having at least an inner pad; a side portion having an opening therethrough for receiving a metal fastener therein; Equipped with each lower pad is configured to act as a seal with the generally planar portion surrounding one of the openings and to provide protection between the second member and a limiter and the fastener housed within one of the openings; the upper pad is configured to act as a seal with the inner pad surrounding one of the openings and to protect an outer area between a head of a corresponding one of the fasteners and the limiter received within one of the openings; 11. A system for sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals, characterized in that the inner pad is configured to function together with the upper pad as a seal surrounding one of the openings and to protect an inner area between the head and the limiter housed within one of the openings.

2. 2. The system for sealing metallic fasteners from an electrolyte in an area of ​​dissimilar metals as recited in claim 1, further characterized by said limiter abutting a corresponding one of said fasteners.

3. 2. The system for sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 1, wherein said first member is one of a housing and a connector housing flange.

4. The system for sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 2 , wherein the second member is one of a housing and a fixture.

5. 3. The system for sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 2, wherein at least one of said generally planar portion of said seal and said corresponding one of said lower pads protects a first area between said fastener threads and said second member from said electrolyte.

6. 6. The system for sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 5, wherein at least one of the generally planar portion of the seal and the corresponding one of the lower pads protects a second area between the corresponding one of the limiters and the second member from the electrolyte.

7. 7. The system for sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 6, wherein at least one of the corresponding one of the generally C-shaped end portions of the seal, the corresponding one of the lower and upper pads, the corresponding one of the extension portions, and the corresponding one of the inner pads protect a third area between the corresponding one of the limiters and the first member from the electrolyte.

8. 8. The system for sealing metal fasteners from an electrolyte in areas of dissimilar metals as recited in claim 7, wherein at least one of the corresponding one of the generally C-shaped end portions of the seal, the corresponding one of the lower and upper pads, the corresponding one of the extension portions, and the corresponding one of the inner pads protect a fourth area between the corresponding one of the fasteners and the corresponding one of the limiters from the electrolyte.

9. 9. The system for sealing metallic fasteners from an electrolyte in areas of dissimilar metals as recited in claim 8, wherein at least one of the corresponding one of the upper pads, the corresponding one of the extension portions, and the corresponding one of the inner pads of the seal protects a fifth area between the corresponding one of the limiters and the corresponding one of the portions below or beneath the head of one of the fasteners from the electrolyte.

10. 1. A method of sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals, comprising: attaching a seal to a first member; placing the first member, with the seal attached, against a second member such that the first member abuts the second member; inserting the fastener through an opening extending through the seal and the first member; threading the fastener into the second member; It is characterized by: the step of attaching the seal to the first member includes the step of covering both end portions of the first member with side cover portions of the seal, The seal is at least a generally planar portion seated between the first member and the second member; and said side cover portions, each of said side cover portions being generally C-shaped and respectively attached to an end of said first member, each of said generally C-shaped side cover portions of said seal having a lower end portion and an upper end portion, each lower end portion having at least a lower pad and each upper end portion having at least an upper pad; an extension portion extending from the upper end portion and having at least an inner pad; Equipped with each lower pad is configured to act as a seal with the generally planar portion surrounding one of the openings and to provide protection between the second member and a limiter and the fastener housed within one of the openings; the upper pad is configured to act as a seal with the inner pad surrounding one of the openings and to protect an outer area between a head of a corresponding one of the fasteners and the limiter received within one of the openings; 13. A method for sealing a metal fastener from an electrolyte in an area of ​​dissimilar metals, characterized in that the inner pad is configured to act as a seal surrounding one of the openings together with the upper pad and to protect an inner area between the head and the limiter housed inside one of the openings.

11. 11. The method of sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 10, further characterized by the step of preventing the occurrence of galvanic corrosion by preventing ingress of the electrolyte in a first area between the threads of the fastener and the second member.

12. 12. The method of claim 11, further characterized by the step of preventing the occurrence of galvanic corrosion by preventing ingress of the electrolyte in a second area between the limiter and the second member, wherein the fastener is inserted into the limiter, the limiter being received within one of the openings and abutting the head of the fastener and the second member.

13. 13. The method of sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 12, further characterized by the step of preventing the occurrence of galvanic corrosion by preventing ingress of the electrolyte in a third area between the limiter and the first member.

14. 14. The method of sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 13, further characterized by the step of preventing the occurrence of galvanic corrosion by preventing ingress of the electrolyte in a fourth area between the fastener and the limiter.

15. 15. The method of sealing a metallic fastener from an electrolyte in an area of ​​dissimilar metals as recited in claim 14, further characterized by the step of preventing the occurrence of galvanic corrosion by preventing ingress of the electrolyte in a fifth area between the limiter and a portion below or beneath the head of the fastener.

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