Patent Publication Number: US-2021172073-A1

Title: Selectively removable marine engine anode

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to anodes for marine applications and, more particularly, relates to selectively removable pencil anodes for marine engines. 
     BACKGROUND OF THE INVENTION 
     Whether for commercial, private, or military applications, the engine of a marine vessel routinely experiences corrosion due to a metal&#39;s contact with salt and brackish water. To combat against corrosion, many vessels, along with other similar devices and assemblies, e.g., oil and gas offshore platforms, construction equipment, and materials handling equipment used to load and unload cargo, employ the use of anti-corrosive materials, systems, and methods. Marine engines, in particular, are at high-risk for experiencing corrosion, wherein said marine engines are typically composed of varying metals and alloys that wear out from rust and corrosion at different rates. One known method to lower the rate of corrosion and to improve the longevity of a marine engine, zinc rods and engine anodes (collectively “anodes”) will be used. 
     One exemplary known anode is depicted in  FIG. 1 . These anodes primarily consist of a material, e.g., zinc, that offers the marine engine protection by essentially sacrificing itself to corrosion, instead of the marine engine. More specifically, the zinc anode  100  may consist of 99.99% or higher of zinc and may be of a rod or cylindrical shape with a threaded end  102  operably configured to threadedly engage with a plug that is operably configured to threaded engage with an engine assembly. In one embodiment, the entire anode may be of the zinc material that may be placed on or around metal components to disrupt the saltwater&#39;s electrolyte current flow that causes corrosion. The anode will begin to corrode and rust, leaving the other important and expensive engine metal materials intact. 
     As seen in  FIG. 1 , the anode depicted therein is often referred to as a “pencil anode” due to its size and shape. Generally, the anode may consist of either a magnesium, aluminum, or zinc material. Magnesium has the most negative electro potential of the three (see galvanic series) and is more suitable for areas where the electrolyte (soil or water) resistivity is higher. This is usually onshore pipelines and other buried structures, although it is also used on boats in fresh water and in water heaters. Zinc and aluminum are generally used in saltwater, where the resistivity is generally lower. Typical uses are for the hulls of ships and boats, offshore pipelines and production platforms, in salt-water-cooled marine engines, on small boat propellers and rudders, and for the internal surface of storage tanks. 
     Zinc, however, is considered a reliable material, but is not suitable for use at higher temperatures, as it tends to passivate (the oxide formed shields from further oxidation); if this happens, current may cease to flow, and the anode stops working. Zinc has a relatively low driving voltage, which means in higher-resistivity soils or water it may not be able to provide sufficient current. However, in some circumstances—where there is a risk of hydrogen embrittlement, for example this lower voltage is advantageous, as overprotection is avoided. When employed as a rod, or pencil anode, the rod will be both dense and heavy to ensure that it remains attached to the metal component and will last for a very long time when submerged in saltwater. However, in time the zinc will completely corrode away. 
     Regardless the material, those known pencil anodes have significant disadvantages and drawbacks. In many instances, the pencil anode becomes significantly corroded if not changed right away, thereby bonding with the plug it is attached to. Therefore, to replace the pencil anode, the user is also required to replace the plug. This is a costly and time-consuming endeavor for the user. Furthermore, when attempting to remove these corroded pencil anodes, most will be become brittle and break, thereby preventing the anode from being completely removed. This too requires complete replacement of the plug and also generates debris that can be harmful to the user replacing the anode and can also damage the engine. 
     Therefore, a need exists to overcome the problems with the prior art as discussed above. 
     SUMMARY OF THE INVENTION 
     The invention provides a selectively removable marine engine anode that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that enables effective, efficient, safe and convenient coupling and uncoupling of an anode to an engine motor, in particular a marine engine motor. 
     With the foregoing and other objects in view, there is provided, in accordance with the invention, a selectively removable engine anode having an anode base having a first end, a second end opposing the first end, a longitudinal length separating the first and second ends, a threaded configuration disposed proximal to the first end and on an outer surface of the anode base, a flanged platform extending radially along the longitudinal length to define an outer flange diameter, and a cantilevered retention member with first member end directly coupled to the flanged platform, including the second end of the anode base, and defining a retention member diameter less than the outer flange diameter. The assembly also includes a galvanic anode with a first anode end coupled to the flanged platform, a second anode free end opposing the first anode end, and an anode length separating the first anode end and the second anode free end, wherein the galvanic anode and the flanged platform encapsulating the cantilevered retention member. 
     In accordance with a further feature of the present invention, the galvanic anode is of a cylindrical shape and has a uniform diameter spanning the anode length. 
     In accordance with yet another feature of the present invention, the outer flange diameter and the uniform diameter are substantially identical. 
     In accordance with an additional feature of the present invention, the galvanic anode is substantially of at least one of a zinc material, an aluminum material, and a magnesium material. 
     In accordance with another feature, an embodiment of the present invention includes the cantilevered retention member also includes a retention member length separating the first member end and the second end, wherein the second end is the terminal end of the cantilevered retention member and an arcuate notch defined thereon along the retention member length, wherein the arcuate notch having a portion of the galvanic anode disposed therein. 
     In accordance with yet another feature, an embodiment of the present invention also includes the cantilevered retention member having a distal portion continually tapering in diameter until reaching the terminal end of the cantilevered retention member. 
     In accordance with an additional feature, an embodiment of the present invention also includes the flanged platform having a lower surface and an upper surface opposing the lower surface and substantially planar. 
     In accordance with an exemplary feature, an embodiment of the present invention also includes an engine plug having a lower end, an upper end defining a plug aperture and opposing the lower end, a plug length separating the lower and upper ends of the engine plug, and defining and enclosing, with a plug inner sidewall surface, a plug channel spanning from the plug aperture into engine plug along the plug length. The engine plug also has an outer threaded configuration disposed proximal to the upper end of the engine plug and on an outer surface of the engine plug and having an inner threaded configuration disposed proximal to the upper end of the engine plug and on the plug inner sidewall surface, the inner threaded configuration of the engine plug selectively removably coupled to the threaded configuration of the anode base and the outer threaded configuration of the engine plug operably configured to be selectively removably couplable to a threaded engagement on a marine engine. 
     In accordance with yet another feature, an embodiment of the present invention also includes the anode base having an attachment portion with the threaded configuration disposed thereon, including an upper end disposed proximal to the flanged platform, including the first end, and defining an attachment length separating the first end and the upper end of the attachment portion, wherein the plug channel only partially spans the plug length and is of a length greater than the attachment length. 
     In accordance with an additional feature, an embodiment of the present invention also includes the engine plug having a polygonal nut disposed proximal to the lower end of the engine plug and surrounding the attachment portion. 
     The present invention also includes a selectively removable engine anode having an anode base of a substantially rigid metallic material having a first end, a second end opposing the first end, a longitudinal length separating the first and second ends, a threaded configuration disposed proximal to the first end and on an outer surface of the anode base, a platform disposed on the longitudinal length, and a cantilevered retention member. The cantilevered retention member extends upwardly from the platform, has the second end of the anode base, and has a retention member length separating the second end and the platform, wherein the second end is the terminal end of the cantilevered retention member. The cantilevered retention member also defines an arcuate notch defined thereon along the retention member length. The assembly also has a galvanic anode with a second anode free end and surrounding and directly coupled to the cantilevered retention member, wherein the arcuate notch has a portion of the galvanic anode disposed therein. 
     In accordance with an additional feature, an embodiment of the present invention also includes the platform having a flanged portion spanning circumferentially and extending radially along the longitudinal length of the anode base to define an outer flange diameter, wherein the cantilevered retention member includes a first member end directly coupled to the flanged portion of the platform and defines a retention member diameter less than the outer flange diameter. 
     In accordance with yet another feature, an embodiment of the present invention also includes the galvanic anode having a first anode end coupled to the flanged platform and opposing the second anode free end and having an anode length separating the first anode end and the second anode free end, the galvanic anode and the flanged platform encapsulating the cantilevered retention member. 
     Although the invention is illustrated and described herein as embodied in a selectively removable marine engine anode, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. 
     Other features that are considered as characteristic for the invention are set forth in the appended claims. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale. 
     Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The term “providing” is defined herein in its broadest sense, e.g., bringing/coming into physical existence, making available, and/or supplying to someone or something, in whole or in multiple parts at once or over a period of time. Also, for purposes of description herein, the terms “upper”, “lower”, “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof relate to the invention as oriented in the figures and is not to be construed as limiting any feature to be a particular orientation, as said orientation may be changed based on the user&#39;s perspective of the device. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. 
     As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. In this document, the term “longitudinal” should be understood to mean in a direction corresponding to an elongated direction of the anode assembly or galvanic anode, spanning from the upper and lower ends thereon. As used herein, the term “wall” is intended broadly to encompass continuous structures, as well as, separate structures that are coupled together so as to form a substantially continuous external surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention. 
         FIG. 1  is a perspective view of a prior art galvanic anode; 
         FIG. 2  is a perspective view of a selectively removable engine anode having an anode base and a galvanic anode coupled thereto in accordance with one embodiment of the present invention; 
         FIG. 3  is perspective close-up view of the anode base in  FIG. 2  unattached to the galvanic anode in accordance with one embodiment of the present invention; 
         FIG. 4  is another perspective view of the selectively removable engine anode in  FIG. 2 ; 
         FIG. 5  is another perspective close-up view of the selectively removable engine anode in  FIG. 3 ; 
         FIG. 6  is a perspective close-up view of a plug for use with the selectively removable engine anode depicted in  FIG. 2  in accordance with one embodiment of the present invention; 
         FIG. 7  is a perspective close-up view of the plug in  FIG. 6  selectively removably coupled to the engine anode base depicted in  FIG. 3  in accordance with one embodiment of the present invention; 
         FIG. 8  is an elevational side view of the engine anode base depicted in  FIG. 3  in accordance with an exemplary embodiment of the present invention; 
         FIG. 9  is a cross-sectional view of the engine anode base in  FIG. 8  along section lines  8 - 8  in accordance with one embodiment of the present invention; 
         FIG. 10  is an elevational side view of an engine anode base in accordance with an exemplary embodiment of the present invention; and 
         FIG. 11  is a cross-sectional view of the engine anode base in  FIG. 10  along section lines  10 - 10  in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. 
     Referring now to  FIGS. 2-3 , one embodiment of the present invention is shown in perspective views.  FIGS. 2-3  show several advantageous features of the present invention, but, as will be described below, the invention can be provided in several shapes, sizes, combinations of features and components, and varying numbers and functions of the components. The first example of a selectively removable engine anode  201  assembly, as shown in  FIGS. 1-2 , includes an anode base  200  coupled to a galvanic anode  202 . With brief reference to  FIGS. 6-7 , it can be seen that the anode base  200  (and attached galvanic anode) is operably configured to selectively couple and uncouple to a plug  600  that is also operably configured to selectively couple and uncouple to a coupling member, e.g., threaded port, on a marine engine. As such, the user is able to quickly, effectively, and efficiently protect metal structures from corrosion using the galvanic anode  202 . 
     The galvanic anode  202  may be made from a metal alloy with a more “active” voltage (more negative reduction potential/more positive electrochemical potential) than the metal of the structure desired to be protected. The difference in potential between the two metals means that the galvanic anode  202  corrodes, so that the galvanic anode  202  is consumed in preference to the structure. Generally, there are three main metals used as galvanic anodes, i.e., magnesium, aluminum and zinc. The anode base  200  and the plug  600  are preferably of a substantially rigid material, e.g., brass, bronze, stainless steel, or other (preferably conductive) metal, ceramic, or alloy, having a Rockwell B hardness of approximately 60-150. 
     Referring to  FIGS. 2-3 ,  FIGS. 5-6 , and  FIG. 8 , the anode base  200  has a first end  300 , a second end  302  opposing the first end  300 , and a longitudinal length  500  separating the first and second ends  300 ,  302 . In some embodiments, the “end” may be referred to as the terminal end of a component or object of the assembly  201 . The anode base  200  also includes a threaded configuration  304  disposed proximal to the first end  300  and on an outer surface  306  of the anode base  200 , thereby enabling coupling and rotational and/or linear translation. Said another way, the threaded configuration  304  may be disposed at or near, within approximately 10% of the overall length, the first end  300  of the anode base  200  and enable the anode base  200  to removably couple (in a locked configuration, at least longitudinally) with a plug  600  (shown in  FIG. 6 ). Additionally, while the figures depict one threaded configuration, other threaded configurations are covered under said description, e.g., tongue-and-groove configurations, snap-fit configuration, etc. 
     The anode base  200  may also include a flanged platform  308  extending radially along the longitudinal length  500  to define an outer flange diameter  800 . In other embodiments, the platform may be a juncture or point where the threaded configuration  304  spans into a cantilevered retention member  310  or section of the anode base  200 . Beneficially, however, the flanged platform  308  generates an effective support, wall, and/or bonding surface for the galvanic anode  202 , e.g., through an over molding, injection molding, casting, or other manufacturing process. The flanged platform  308  also prevents splashing when inserting or removing the assembly  201  into an engine port. In one embodiment, the platform  308  may circumferentially span around the cantilevered retention member  310 , thereby forming an annular structure and support surface. The flanged platform  308  may include a lower surface  318  and an upper surface  320  opposing the lower surface  318 , wherein the upper surface  320  is substantially planar, i.e., relatively flat to enable level attachment of the first anode end  400  of the galvanic anode  202  thereto (best shown in  FIG. 4 ). The flanged platform  308 , namely the upper surface  320  thereon, may radially project outwardly form the cantilevered retention member  310 , or the longitudinal axis of the cantilevered retention member  310 , at a substantially perpendicular angle, i.e., 90°+/−10°. 
     The cantilevered retention member  310  may also include a first member end  312  directly coupled to the flanged platform  308  and may also include the second end  302  of the anode base  200 , which may be the terminal end, or tip, of the cantilevered retention member  310 . With reference to  FIG. 8 , the cantilevered retention member  310  may also define a retention member diameter  802  less than the outer flange diameter  800 , thereby enabling the galvanic anode  202  to effectively surround the cantilevered retention member  310  and be supported and/or couple/bond to the flanged platform  308 . The cantilevered retention member  310  may also include a retention member length  804  separating the first member end  312  and the second end  302 , wherein the second end  302  is the terminal end of the cantilevered retention member  310 , and an arcuate notch  314  defined thereon along the retention member length  804 . The concave notch  314 , which preferably has a recess depth of approximately 0.025 inches or approximately 10% of the overall diameter, also enables the galvanic anode  202  to effectively surround and bond/couple with the cantilevered retention member  310 . To that end, when completely assembled together, the arcuate notch  314  has a portion of the galvanic anode  202  disposed therein, thereby preventing inadvertent dislodgment or failure in the longitudinal direction or axis  812  of the cantilevered retention member  310 . The concave or arcuate notch  316  may be of another shape, but said shape produces a higher adhesion bond and higher tensile failure point. 
     The cantilevered retention member  310  may also have a distal portion  316  continually tapering in diameter until reaching the terminal end or tip of the cantilevered retention member  310 . In one embodiment, the distal portion  316  will begin tapering approximately 5-10% of the retention member length  804  and may have a tapering angle of approximately 45 with respect to the longitudinal direction or axis  812  of the cantilevered retention member  310 . 
     As best seen in  FIGS. 2-4 , the galvanic anode  202  has a first anode end  400  coupled to the flanged platform  308 , a second anode free end  402  opposing the first anode end  400 , and an anode length  404  separating the first anode end  400  and the second anode free end  402 . The anode length  404  may vary based on the design application and coupling constraints, but may be approximately 2-5 inches. The galvanic anode  202  may have a diameter of approximately 0.25-1 inches and may be of a cylindrical shape. In one embodiment, the galvanic anode  202  has a uniform diameter  204  spanning the anode length  404 . Additionally, the outer flange diameter  800  and the uniform diameter  204  may also be of a substantially identical length, thereby enabling effective coupling thereto and easy insertion and removal of the engine anode  201  into a coupling port on a marine engine. When aimed at applications with high salinity, the galvanic anode  202  is substantially of a zinc material. However, in other embodiments, the galvanic anode  202  may be substantially of an aluminum material, a magnesium material, or other galvanic material. The galvanic anode  202  and the flanged platform  308  encapsulate the cantilevered retention member  310  when assembled together. 
     As discussed above, the anode base  200  and galvanic anode  202  coupled to an engine plug  600  that is operably configured to be selectively removably couplable to a threaded engagement on a marine engine. With reference to  FIGS. 6-8 , the engine plug  600  also includes a lower end  602 , an upper end  604 , defining a plug aperture  610 , and opposing the lower end  602 . A plug length  700  is also defined by the lower and upper ends  602 ,  604  of the engine plug  600 . In one embodiment, the plug length  700  may be approximately 0.5-2.5 inches. The plug  600  may also beneficially define and enclose a plug channel  612  spanning from the plug aperture  610  into engine plug  600  along the plug length  806 . More specifically, it is the plug inner sidewall surface  614  that defines the plug channel  612 . As seen in the figures, the engine plug  600  also includes an outer threaded configuration  606  disposed proximal to the upper end  604  of the engine plug  600  and on an outer surface  608  of the engine plug  600 . The plug  600  also includes an inner threaded configuration  616  disposed proximal to the upper end  604  of the engine plug  600  and on the plug inner sidewall surface  614 . As the figures depict, the inner threaded configuration  616  of the engine plug  600  may be beneficially selectively removably coupled to the threaded configuration  304  of the anode base  200  and the outer threaded configuration  606  may be beneficially selectively removably coupled to an engine port. As such, the user may now effectively, easily, and safely attach and detach a galvanic anode  202  to an engine port. 
     The anode base  200  may also have an attachment portion  808  with the threaded configuration  304  disposed thereon, including an upper end  810  disposed proximal to the flanged platform  308 , and including the first end  300 . The attachment portion  808  may defining an attachment length  806  separating the first end  300  and the upper end  810  of the attachment portion  808 , wherein the plug channel  612  only partially spans the plug length  806  and is of a length greater than the attachment length  806 . As such, the anode base  200  may effectively seat on the plug  600  in a watertight and/or sealed configuration (e.g., using the threaded configuration). The plug  600  may also include a rubber gasket enabling a watertight and/or sealed configuration with the motor port. To effectively tighten the plug  600  to the engine port, the engine plug  600  may also include a polygonal nut  618  disposed proximal to the lower end  602  of the engine plug  600  and surrounding the attachment portion  808 . 
     In one embodiment, the threaded configurations may be one of the following (in inches): ½, ⅝, ¾, ⅞, 1, 1⅛, etc., but should correspond with opposing threading as shown in the figures. Although the figures show a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments.  FIGS. 10-11  also depict another version, i.e., alternative dimensions, of the anode base. Also, two or more steps shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted for the sake of brevity. In some embodiments, some or all of the process steps can be combined into a single process. 
     Additionally, various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the above described features.