Patent Document

BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to an apparatus and method for cooling systems of an internal combustion engine, and more particularly to an anode device and maintenance method for marine engines. 
         [0003]    2. Brief Description of the Related Art 
         [0004]    Many marine engines have a cooling system which involves the introduction of seawater through the heat exchanger engine or manifolds. The engine cooling system generally has one or more threaded openings that are designed to receive a sacrificial zinc anode and plug. These zinc pencils or pencil anodes, as they are often referred to, contain a zinc alloy and usually are supplied with threaded brass plugs. The threaded brass plugs are threaded externally to fit within the threaded opening of the engine cooling system port. The brass plugs also contain internal threads for threading with the zinc anode so that the zinc anode is held within the brass plug. The brass fitting with the zinc anode typically threads into a port of an engine or cooling system so that the anode comes into contact with the raw seawater passing through the system. The zinc anode has a useful life and requires replacement. The replacement of the zinc anode is done to extend the life of marine engine coolant systems, such as, engines, heat exchangers, pipes, condensers, water cooling jackets, and other components that come into contact with the seawater. 
         [0005]    The function of the zinc anode is to reduce corrosion of other components. For example, when two different metals are in contact, electrons will flow from the more negatively charged metal (anode) to the more positive metal (cathode). For example, in cooling systems, dissimilar metals may be in contact through a fluid (e.g., seawater) which acts as an electrolyte. A current may be established which promotes galvanic corrosion. In situations where the metals (e.g., the two different metals) are to be protected from corrosion, an additional metal is introduced so it is available to serve as the anode for both of the other metals (i.e., the metals that are desired to be preserved). The zinc anode is used, and is commonly termed the sacrificial anode, because it is designed to protect the engine cooling system components from degradation due to galvanic corrosion. Providing the sacrificial zinc anode in the form of a plug which is sacrificed as an anode directs this electrolysis to a relatively inexpensive, replaceable component in order to protect the more valuable cooling system or engine components. The zinc anode degrades upon use, and is replaceable, which is much less costly than replacing other, more expensive components of the cooling system. It is possible that other types of metals may be used in alloys with, or as a substitute for zinc, but zinc is a widely used sacrificial anode. 
         [0006]    One of the problems encountered in the replacement of the zinc anode is that the plug containing the zinc anode generally seals an access port to the flow path of the cooling system where the coolant (seawater) passes. Due to the configurations of the cooling systems, there often is seawater present in the cooling system, which emerges from the cooling system when the plug is removed. Even slowly removing the brass plug containing the zinc anode (or a spent zinc anode that is to be replaced), may result in spray or leakage of seawater out of the cooling system and onto surrounding components. The escape of seawater from the cooling system may contaminate or corrode other nearby components, such as, for example, an alternator or starter. In addition, the escaping seawater may build up in the bilge, which then often must be pumped out and rinsed with fresh water. Another problem is that the brass fitting containing the zinc may be difficult to withdraw from the port. In some cases the threads may become stuck, and attempts to remove the brass fitting and the remainder of the spent zinc anode that may be attached to the fitting, may result in pieces of the anode fragmenting off into the cooling system. In some instances, the zinc anode may fall into the engine system and block the passage of the seawater. This could cause engine overheating and potential destruction of the engine and associated components. 
         [0007]    At times, when the maintenance of the zinc anode is not performed in a timely manner, the zinc can corrode away to the point that it cannot be removed from the plug. This requires both a new plug and new anode to be installed. 
         [0008]    A need exists for a device and method that will facilitate maintenance and installation of a zinc anode in an economical manner without the drawbacks of the prior plugs and methods, particularly the escape of water from the cooling-system. 
       SUMMARY OF THE INVENTION 
       [0009]    A method and device are provided for maintaining a marine engine, and more particularly a method and device that permits the installation, removal and replacement of an anode, such as a zinc anode, in a cooling system of a marine engine are provided. 
         [0010]    It is an object of the present invention to provide a device that facilitates installation and replacement of an anode of a marine engine or its cooling system. 
         [0011]    It is an object of the present invention to provide a method for replacing an anode, such as a zinc anode of a marine engine cooling system, in a manner that minimizes or prevents escape of seawater from the cooling system. 
         [0012]    It is an object of the invention to provide a connection and disconnection mechanism that seals the cooling system environment to prevent water from exiting the cooling system environment at the location of the anode plug, during the installation, withdrawal and replacement of an anode. 
         [0013]    It is another object of the invention to provide a method and device that excludes water from the point of attachment between the zinc anode and the plug so the zinc anode may be replaced without the need to replace the plug. 
         [0014]    It is another object of the invention to provide an improved anode plug that minimizes or prevents the escape of fluid from a system in which the anode plug is installed. 
         [0015]    It is another object of the invention to provide an improved anode for installation and use with an anode plug. 
         [0016]    It is another object of the invention to provide an anode that has an indicator that indicates a condition of the anode to indicate when the anode requires replacement. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         [0017]      FIG. 1  is a front sectional view of an embodiment of an anode plug device according to my invention, shown with an anode installed, with the device being shown installed in a structure of a cooling system of a marine engine, the cooling system structure being partially shown, and in a sectional view. 
           [0018]      FIG. 2  is an exploded view of the device of  FIG. 1 , showing the components separately from a cooling structure, with the connector body portions being shown in sectional view. 
           [0019]      FIG. 2   a  is a front elevation view of an alternate embodiment of an anode. 
           [0020]      FIG. 3  is a top plan view of the connecting body portion of the device of  FIG. 1 . 
           [0021]      FIG. 4  is a top plan view of the lower body portion of the device of  FIG. 1 . 
           [0022]      FIG. 5  is a sectional view looking at the front of the device of  FIG. 1 , shown without the anode. 
           [0023]      FIG. 6  is a top plan view of the upper body portion of the device of  FIG. 1 . 
           [0024]      FIG. 7  is a perspective view showing the connector upper body portion and connecting portion together and separate from the other components. 
           [0025]      FIG. 8  is a front sectional view of an alternate embodiment of an anode plug device with an alternate anode. 
           [0026]      FIG. 9  is a perspective view of an alternate embodiment of an anode. 
           [0027]      FIG. 10  is a front sectional view of another alternate embodiment of an anode plug device according to my invention. 
           [0028]      FIG. 11  is an exploded view of the anode plug device of  FIG. 10 , the components being shown separately from the spring and bearings. 
           [0029]      FIG. 12  is another exploded view of the anode plug device of  FIG. 10 , being shown with an anode. 
           [0030]      FIG. 13  is a top plan view of an alternate embodiment of an upper body portion of a connector shown with a connecting mechanism. 
           [0031]      FIG. 14  is a sectional view of the upper body portion of  FIG. 13  shown with an alternate embodiment of an anode. 
           [0032]      FIG. 15  is a front elevation view of an alternate embodiment of an anode. 
           [0033]      FIG. 16  is a front elevation view of another alternate embodiment of an anode. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0034]    Referring to  FIG. 1 , a preferred embodiment of an anode plug device  10  is shown with an anode  100  held therein. The anode plug device  10  is shown according to a preferred embodiment having a connector  11  that has a channel therethrough. According to a preferred embodiment, the connector  11  is illustrated having a lower body portion  11   a , an upper body portion  11   b , and a connecting portion lie. The connector  11  preferably has a threaded portion  13  that is matingly threaded for connection to a threaded bore  201  of an engine cooling system component, such as the pipe  200  (or other structure to which the device  10  is mounted). The connector  11  preferably has sealing means comprising a sealing mechanism for sealing the passage of seawater from escaping through the connector  10  when the anode  100  is removed. The sealing mechanism preferably comprises a sealing component. According to some embodiments, the sealing component may comprise a spring-loaded wafer valve. According to other embodiments, the sealing component may comprise an elastomeric seal. A preferred embodiment is illustrated, where a sealing mechanism is provided that includes at least one sealing member. According to some embodiments, a connector  11  has a chamber  14  in which a first sealing member  15  is disposed, the first sealing member  15 , according to a preferred embodiment, comprises a cross-slit valve, having an opening  15   a . As shown in  FIG. 2 , in the exploded view, the sealing means is shown, and, according to a preferred embodiment, a first sealing member is illustrated being configured as cross-slit valve  15 . According to a preferred embodiment, the cross-slit valve  15  preferably is elastomeric. Preferably, the sealing means may include a second sealing member  16 , which may be provided as an additional sealing point to further facilitate the sealing properties of the device  10 . Alternately, although not shown, according to an alternate embodiment, the sealing members  15 ,  16  may be provided as a single member. The second sealing member  16  has an opening  16   a  therein, as shown in  FIG. 2 . According to a preferred embodiment, the second sealing member  16  seals against an annular flange  18  of the connecting portion lie. The connecting portion  11   c  is shown in  FIGS. 2 and 3  having an aperture  20  therein and bores  21  that align with bores  22  of the lower body portion  11   a . The lower body portion bores  22  preferably are threaded to receive matingly threaded fasteners, such as bolts (not shown) that connect the connecting portion  11   e  with the lower body portion  11   b . The connecting body portion  11   e  ( FIG. 3 ) also has bores  21   a ,  21   b  that preferably may be threaded and align with bores  34   a ,  34   b , respectively, of the upper body portion  11   b . Bolts (not shown) may be installed in the bores  21   a ,  21   b  and  34   a ,  34   b  to connect the upper body portion  11   b  with the connecting body portion  11   c . According to a preferred embodiment, a biasing mechanism is provided to bias the valve  15  to a sealing position against the body of the anode  100 , and, according to some embodiments, to bias the valve  15  to seal the valve opening  15   a  closed when the anode  100  is not present in the valve opening  15   a . According to a preferred embodiment, the biasing mechanism includes a garter spring  24 , which, for example, preferably may be a coil spring tied or secured end-to-end to provide an even force around the valve  15 . The garter spring  24  preferably maintains the valve  15  in sealing engagement against the anode  100  by keeping the valve  15  against the anode  100  (or, when the anode is not present within the valve opening  15   a , closes the valve opening  15   a  by exerting a biasing force on the valve  15 ). An annular groove  25  preferably is disposed in the lower body portion  11   a  in which the spring  24  is disposed, and, as shown in  FIG. 1 , in the assembled view, the spring  24  engages the valve  15 .  FIG. 5  shows the device  10  with the anode  100  removed therefrom, and illustrates the biasing of the spring  24  against the valve  15  to close the valve opening  15   a.    
         [0035]    According to a preferred embodiment, as shown in  FIG. 2 , the cap member  12  is provided having a bore  26  therein which preferably is threaded with mating threads that engage the threaded end  101  of the anode  100  to hold the anode  100  in engagement with the cap member  12 . Alternately, an anode that is not threaded may be turned into the threads of the cap member  12  to be releasably secured therein. Alternately, the anode may be provided without a cap member, and according to some embodiments, the anode may have a handle or gripping means to facilitate rotating the anode (see  FIGS. 8 and 9 ). The connector  11  preferably has connecting means for providing a removable connection between the connector  11  and the anode  100 . The connecting means provides a connection to secure the anode  100  on the connector  11 , and permits removal of the anode  100  from the connector  11  as needed or desired to replace, install, maintain or inspect the anode  100 , or to maintain the structure to which the device  10  is installed, such as, for example, a pipe  200  of an engine system. 
         [0036]    According to a preferred embodiment, connecting means is shown comprising a connection mechanism. As shown in the exploded view of  FIG. 2 , according to a preferred embodiment, the anode  100  is provided having pins  102  that connect to the connector  11 . The connector upper body portion  11   b  preferably has an engaging mechanism that engages the anode pins  102  to connect the anode  100  the device  10 . According to a preferred embodiment, the engaging mechanism may capture the anode  100  by capturing pins  102  provided on the anode  100 . According to a preferred embodiment, alternately, the anode  100  may be provided with an integral cap. The upper body portion  11   b  preferably has a bore  33  therethrough in which the anode  100  (or cap member sleeve  151  in the embodiment shown in  FIG. 8 ) may pass through. The pins  102  engage the outer slots  27  (see  FIGS. 1 ,  2 ,  5  and  6 ) provided in the upper body portion lib. As shown in  FIGS. 6 and 7 , the upper body portion  11   b  has outer slots  27  and inner slots  28  provided therein for receiving the pins  102  of the anode  100 . The slots  27  and  28  are connected by a channel  29 , and according to a preferred embodiment, a pair of slots  27 ,  28  is provided on opposite sides of the upper body portion  11   b . For example, according to the exemplary embodiment, in  FIG. 1 , an anode  100  is connected to a cap member  12 , and the anode  100  is connected to the upper body portion  11   b  by way of the pin engagement with the slots  27 ,  28  and channel  29 . According to one embodiment, the slots  27 ,  28  and channel  29  are provided at diametrically opposite sides of the upper body portion  11   b . Preferably, the connection is made by aligning the pins  102  with the outer slots  27 . The pins  102  are received in the outer slots  27 , and the anode  102  is rotated to move the pins  102  along the channel  29 . Preferably, the anode  102  rotation may be facilitated with downward pressure (in the direction toward the lower body portion  11   a  end) to move against resistance of a biasing mechanism that urges the pins  102  upward. When the pins  102  reach the inner slots  28 , the pins  102  are cammed upwardly into the slots  28  by the action of a biasing mechanism. The biasing mechanism, according to a preferred embodiment, includes a wafer spring or wave washer  31  that preferably has an opening (see  FIG. 1 ) to permit passage of the anode  100  therethrough. Preferably, a camming washer, such as, for example, a stainless steel washer  30  with an opening  30   a  (see  FIG. 2 ), is disposed above the wave washer  31  and provides a camming surface for the pins  102  to travel along when the pins  102  are being rotated for installation or removal from the device  10 . 
         [0037]    A handle preferably may be provided on the anode  100  or cap  12  to provide a means for gripping the anode  100  or cap member  12  to facilitate rotation and removal of the anode  100  (and any cap thereon) from the connector  11 . Referring to  FIG. 2   a , according to a preferred embodiment, an alternate anode embodiment  100 ′ is shown having a handle that may comprise a pin, or pins,  56 ,  57 . The pins  56 ,  57  may comprise a single pin that is passed through the upper portion of the anode  100 ′ (or a cap). Similar pin handles  156 ,  157  are shown in  FIG. 8 , and pins  156 ′,  157 ′ are shown in  FIG. 9 . Referring to  FIG. 2   a , the pins  56 ,  57  are shown in the exemplary anode  100 ′ and may be integrally provided with the anode  100 ′, or, alternately, may be separately provided, and attached, for example, through a horizontal bore (not shown) of the anode  100 ′. The anode pins  102 ′ also connect with the device  10  through the connection to the upper body portion  11   b , as shown and described herein in connection with the pins  102 . 
         [0038]    Preferably, the anode pins  102  also make contact with the upper body portion  11   b  when the anode  100  is installed on the device  10 , so as to maintain the anodic contact between the anode  100  and the system structure  200 , which, according to ta preferred embodiment, is done by having electrical conductivity maintained between the anode  100  and upper body portion  11   b , through the connector  11 , and according to the preferred connector embodiment, by maintaining electrical conductivity between the upper, connecting and lower body portions, respectively  11   b ,  11   c , and  11   a . According to a preferred embodiment, the connection mechanism comprises a washer  30 , such as for example a stainless steel washer, and a wave washer  31 , which are disposed in a recess  32  of the of the upper body portion  11   b  of the connector  11 . 
         [0039]    According to a preferred embodiment, the anode  100  is releasably installed on the connector  11   b . One preferred method of installing the anode  100  on the connector  11  is to position the anode pins  102  within the outer slots  27 , and apply a downward pressure against the force of the wave washer  31  to lower the pins  102 . The anode  100  is then rotated to move the pins  102  along the channel  29  to locate the pins  102  in the inner slots  28 , whereupon release of the downward pressure releases the force applied on the wave washer  31 , and the pins  102  are biased upwardly into a locking position where the pins  102  are seated within the inner slots  28 . Referring to  FIG. 1 , a pin  102  is shown in the outer slot  27 . To secure the anode  100  on the device  10 , the downward pressure lowers the pin  102 , whereupon it may be rotated (in the embodiment illustrated, in a clockwise direction) until it reaches the locking or inner slot  28 . The other pin  102  also is lowered and rotated to the oppositely disposed slots  28 . According to a preferred embodiment, the inner slots  28  are disposed higher than the channels  29  that connect each outer slot  27  with an inner slot  28 . Alternately, a single channel  29  may be provided to connect the outer slots  27  and inner slots  28 , or alternately, two channels  29  may be provided, each connecting an outer slot  27  with an inner slot  28 . 
         [0040]    Likewise, removal of the anode  100  from the device  10  is accomplished in a similar manner, in reverse, by depressing the top of the anode  100  or cap member  12  to lower the pins  102  from the inner slots  28 , and rotating the anode  100  (or cap member  12  that carries the anode  100 ) counterclockwise (according to the embodiment illustrated) so as to bring the pins  102  into alignment with the outer slots  27 . The anode  100  (or cap member carrying the anode  100 ) is then lifted to remove it from the upper body portion  11   b .  FIG. 6  shows a top view of the upper body portion  11   b  and slots  27 ,  28 . 
         [0041]    The device  10  preferably is used with a zinc anode  100 . According to a preferred method, the device  10  may be supplied in one or more components, and may be supplied with an anode  100 , such as a zinc anode, or may be supplied separately from the anodes. Although a zinc anode is described according to preferred embodiments, the anode  100  may be composed of other suitable materials, such as, for example, zinc alloys or other metals, metal compositions and alloys. According to a preferred embodiment, the anode  100  is secured to the cap member  12 . Preferably, this is accomplished by threading the anode  100  onto the cap member  12  by engaging the anode threads  101  with the cap member threads  26 . (See  FIG. 2 ) If the installation involves a replacement anode, then a degraded anode which is carried on the cap member  12  is removed from the cap member  12  (preferably, by unscrewing it from the cap), and a new anode  100  installed. Alternately, although not shown, an anode may be configured having an integral cap, or alternately, in place of the cap  12 , the anode may be provided with handles or pins (see, e.g.,  FIG. 2   a ). According to another alternate embodiment, the cap member may be configured with arms or pins that are received in slots, such as, for example, those outer slots  27  and inner slots  28  of the upper body portion  11   b , and an anode may be secured to the cap member by screwing the threaded end of the anode to the cap member. In this alternate embodiment, the spacing and location of the slots in the alternate embodiment (like those slots  27 ,  28 ) is provided to accommodate pins of the cap. The anode  100 , whether through its contacts between the pins  102  and upper body portion  11   b  or through the anode contact with the cap member  12  and the cap member contact with the upper body portion  11   b , is in a conductive relationship with the structure to which the device  10  is attached (such as the pipe  200 ). Preferably, the upper body portion  11   b , lower body portion  11   a , and connecting portion  11   e  are conductively connected to permit electrical conductivity between the anode  100  and a structure to which the device  10  is attached. 
         [0042]    Preferably, the device  10  is used by installing the connector  11  on the cooling system structure, such as, for example a pipe  200 . According to a preferred embodiment, the connector threaded portion  13  is connected to a matingly threaded bore  201  of the structure or pipe  200 . According to one option, for an initial installation, the device  10  may be installed as a unit, with the connector  11 , cap member  12  and anode  100  pre-connected together. According to a preferred option, for an initial installation or for subsequent installations, the connector  11  is installed on a structure before the cap member  12  and anode  100  are installed on the connector  11 . The connector  11  carries the sealing member or cross-slit valve  15  therein. The connector  11  is installed by connecting it to the threaded bore  201  of the structure  200 . This may be done by rotating the connector  11  and tightening the connector mating threads  13  against the threaded bore  201 . The connector  11  may remain installed on the structure  200  when subsequent replacements of the anode  100  are to be made. According to a preferred embodiment of the method, the connector  11  remains attached to the structure  200 , and the cap member  12  with the anode  100  (e.g., the remaining portion of the anode  100 ) is removed from the device  10  by depressing the cap member  12  to lower the pins  102  in the inner slots  28 , and rotating the cap member to rotate to pins  102  along the channel  29  into alignment with the outer slots  27  of the upper body portion  11   b . The cap member  12  and any portion of the anode  100  attached thereto is then withdrawn from the connector  11  by lifting the cap member  12  and remaining anode portion (in the case where the spent anode is being removed) from the connector  11   b . According to the embodiments where the anode  100 ′ includes pins  56 ,  57  ( FIG. 2   a ), the pin handles  56 ,  57  may be used to rotate the anode  100 ′ to install and remove the anode from the device  10 . 
         [0043]    According to a preferred embodiment, the connector  11  remains installed on the structure (such as the pipe  200 ), and the cap member  12  is removed from the device  10  along with any remaining the portion of the anode  100 . In many instances, when about 70% of the anode has been used, the anode should be replaced. The replacement of a worn anode before it is entirely consumed preferably is done to prevent potential corrosion of the components of the cooling system, engine or other structure to which the device  10  is attached and for which the anode  100  is used as a sacrificial anode. 
         [0044]    The device  10  prevents or minimizes water (or other fluid) from escaping from the system, such as the pipe  200  that contains a fluid (e.g., seawater for cooling marine engines), since, as the removable components, such as, for example, the cap member  12  and anode  100 , are disconnected from the connector  11 , the sealing means, in particular, the first sealing member  15  covers the opening through which the anode  100  previously occupied (see  FIG. 5 ) to block the passage of water from the structure or pipe  200 . In this manner, according to a preferred embodiment, the anode  100  and cap member  12  may be removed from the connector  11 . The withdrawal of the anode  100  withdrawals the anode  100  from the opening  15   a  of the cross-slit valve  15 , and the cross-slit valve  15  closes to seal the opening  15   a  that the anode  100  once occupied. 
         [0045]    The first sealing member  15  preferably, the cross-slit valve also facilitates sealing, such as when the anode  100  is consumed (by galvanic corrosion) and when the anode  100  recedes to a point above the valve  15  (relative to the direction of the cap member  12 ). The valve opening  15   a  will close to block passage of water. The closing of the cross-slit valve  15  is aided by the garter spring  24 , which constricts the valve  15  to close the valve opening when the anode  100  is no longer present. According to a preferred embodiment, preferably, the sealing member  15  is constructed from a resilient and suitably corrosion resistant material, such as a substantially non-reactive component, like silicone, or other elastomer, so that the material may be moved aside to provide the opening for passage of the anode  100  when the anode is present. According to a preferred embodiment, a second sealing member  16  is shown above the first sealing member  15 , relative to the cap member  12  of the device  10 , and provides a further blockage to potential water that may escape from the cooling system (or other structure, such as the pipe  200 ) when the cap member  12  and anode  100  are removed for replacement of the anode  100  (or when the cap member  12  is removed to check the anode  100  wear condition). The second sealing member  16  preferably may be an elastomeric component, and more preferably may be made from a substantially non-reactive component, such as silicone. According to one embodiment, the second sealing member  16  preferably has at least one opening  16   a  (see  FIG. 2 ) to permit the anode  100  to pass through. Alternately, the second sealing member  16  may be flexible so as to recede to close or substantially close the opening when the anode  100  is not present. For example, according to one embodiment, when the anode  100  is withdrawn from the connector  11 , the second sealing member  16  constricts against the anode  100  as the anode  100  is being withdrawn. This provides a secondary sealing (when used in an embodiment with the first sealing member  15 ). According to some embodiments, the second sealing member  16  may constrict to close the opening  16   a , when the anode  100  is withdrawn from opening  16   a.    
         [0046]    The cap member  12  may be removed from the connector  11 , and a new anode  100  installed to replace the spent anode. Preferably, the worn remainder of the anode  100  is removed from the cap member  12 , and a new anode  100  installed (by screwing the threads  101  of a new anode to the threads  26  of the cap member  12 ). Where a cap member is integral with an anode, or is not provided, the anode may be replaced with an anode having an integral cap or no cap (see  FIG. 2   a ). 
         [0047]    The cap member  12  and anode  100  preferably are installed on the connector  11  by inserting the leading end of the anode  100  through the sealing means or sealing component, such as the second sealing member  16  and first sealing member  15 . Preferably, the first sealing member  15  seals around the anode  100  to block water from passing through the device  10  (e.g., from the structure out through the device  10 ). 
         [0048]    According to a preferred embodiment, the device  10  is constructed having means for connecting the device  10  to a structure, such as, for example, a structure that may be an engine or a cooling system component of an engine. The means for connecting the device to a structure is illustrated, according to a preferred embodiment, comprising a connector  11 . The device  10  preferably includes means for removably coupling an anode with the means for connecting the device to a structure. The means for removably coupling an anode with the means for connecting the device to a structure is shown, according to a preferred embodiment, comprising a connecting mechanism that removably connects the anode  100  with the connector  11 . The means for removably coupling the anode with the means for connecting the device to a structure preferably comprises pins  102  that are received in outer slots  27  on the connector  11 , which are rotated through a channel  29  to inner grooves  28 , where the pins  102  are retained by the biasing force of a retaining member. The retaining member, according to preferred embodiments, may be a wave washer, and may include a camming surface such as a washer disposed on the wave washer. Means for holding an anode  100 , according to a preferred embodiment, preferably is provided to hold the anode  100  to the cap member  12 , and, in a preferred embodiment, is shown comprising threads  26  provided on the cap member  12  into which matingly associated threads  101  of an anode  100  may engage. Optionally, an alternate configuration may be used where pins are provided on the cap member. The device  10  preferably includes sealing means for sealing the structure environment so as to minimize or prevent escape of fluid from the structure to which the device  10  is attached. Preferably, the sealing means seals against the anode  100  so as to prevent escape or leakage of fluid from the engine or structure compartment that contains the fluid into the area where the anode  100  is connected to or held by the device  10 . According to a preferred embodiment, the sealing means is shown comprising a seal, and, according to one preferred embodiment, the sealing means comprises, a cross-slit valve or seal  15 . In a preferred arrangement, the anode  100  passes through the cross-slit valve  15  when the anode  100  is installed. According to one preferred embodiment, a constricting member constricts the valve  15  against the anode  100 , or, when the anode  100  is not present, to a closed position to close the valve opening  15   a . According to a preferred embodiment, the connecting member may comprise a garter spring  24 . Preferably, the cap member  12  holds the anode  100 . 
         [0049]    Although the device  10  and method have been described, the cap member  12  (when used) preferably is connected to the connector  11  with the anode  100  already installed in place on the cap member  12 . The anode  100  and cap member  12  may be connected together and then installed on the connector  11  which already has been installed on the pipe  200 . According to an alternate method, when no fluid is present in the structure, as in an initial installation or dry installation, the cap member  12  and anode  100  may be installed on the connector  11 , and the device  10 , with the cap member  12 , anode  100  and connector  11  connected together (with the cap member  12  and anode  100 ), may be installed on the structure, such as, for example the pipe  200 , by securing the threads  13  of the connector  11  to the threaded bore  201  of the structure  200 . Although a single bore  201  is shown in the structure, there may be a plurality of bores on the cooling system components, and a device  10  may be installed in each bore. Although the structure to which the device  10  is installed is illustrated as a pipe  200 , it is understood that the structure to which the device  10  may be attached may comprise components other than a pipe  200 , such as, for example, cooling system manifolds or other structures. In addition, the devices shown and described herein may be constructed in different sizes, and with different sized components, in order to accommodate different size bores and openings in structures to which the devices are attached. The device  10 , and in particular, the connector  11 , may be comprised of a conductive material that has resistance to corrosion. One example of a material from which the connector may be constructed is brass. Other examples of material from which the connector may be constructed is metal and metal alloys, including stainless steel, or other materials coated to provide suitable conductivity between the anode and structure. The device  10  may be constructed with different size components in order to be used with different sized anodes. 
         [0050]    Referring to  FIG. 8 , an alternate embodiment of an anode plug device  110  is shown having a connector  111  with a channel therethrough, the connector  111 , according to a preferred embodiment, having a lower body portion  111   a , an upper body portion  111   b , and a connecting portion  111   e . The connector  111  preferably has a threaded portion  113  that is matingly threaded for connection to a threaded bore, such as the bore  201  of an engine cooling system component or pipe  200  (shown in  FIG. 1 ). The connector  111  has a chamber  114  in which a first sealing member  115  is disposed, the first sealing member  115 , as shown and discussed herein in connection with the embodiment shown in  FIGS. 1-7 , may comprise a cross-slit valve, having an opening  115   a . A second sealing member  116  is provided above the first sealing member  115 . Preferably, the cap member  112  has a sleeve  151  with a threaded bore  152  for connecting with a threaded shaft  301  of a matingly threaded anode  300 . A cap member  112  (which is an optional member) is shown according to a preferred configuration constructed as a post  155  with arms  156 ,  157  extending outwardly from the post  155  to provide a handle for gripping and facilitating rotating of the cap member  112  and anode  300  attached thereto. The installation, maintenance and removal and replacement of the anode  300  may be done as shown and described herein in connection with the device  10 , except that the cap member  112  is released and removed from the connector  111 , and the anode  300  (or portion of it that remains) is unscrewed from the cap member sleeve  151 , and a new anode  300  is installed on the sleeve  151 . The withdrawal of the sleeve  151  from the channel  114  (when the cap member  112  is released from the device  110  and withdrawn), releases the pressure on the valve  115  and spring  124 , and the spring  124  bias facilitates closing of the valve opening  115   a . According to a preferred embodiment, the cap member  112  is secured on the connector  111  with suitable connecting means, such as, for example, the pin and slot arrangement shown and described in connection with the device  10  of  FIGS. 1-7 . Preferably, the cap member  112  has pins  160  that are disposed on the upper end of the sleeve  151 , preferably, on opposite sides thereof; for receipt into slots and channels, such as the slots  27 ,  28  and channels  29  shown and described herein in connection with the device  10  of  FIGS. 1-7 . Preferably, the upper body portion  111   b  includes the slots  27 ,  28 , and channels  29 , as shown and described herein in connection with the embodiment of  FIGS. 1-7 . The pins  160  facilitate securing of the cap member  112  (when used) and anode  300  attached thereto onto the connector  111 , and releasing of the cap member  112  and anode  300  from the connector  111 . Installation of the device  110  to a structure may be carried out as shown and described in connection with the device  10  (which is shown installed on a structure  200 ). 
         [0051]      FIG. 9  illustrates an alternate embodiment of a cap member  112 ′ having a sleeve  151 ′ and being constructed for use with an anode  300 ′, which has pins  160 ′ for facilitating a connection with a connector, such as, for example, the connector  11  or  111 . The cap member  112 ′ preferably has a handle formed from two upper pins  156 ′,  157 ′. The cap member sleeve  151 ′ preferably has a mechanism for connecting an anode  300 ′, which according to a preferred embodiment, the mechanism is shown including a threaded bore  152 ′ which may receive the threads  301 ′ of the anode  300 ′. 
         [0052]    Referring to  FIGS. 10-12 , an alternate embodiment of an anode plug device  210  is shown (with an anode  400  shown in  FIG. 12 ). The anode plug device  210  has a connector  211  and a cap member  212 . The connector  211  is illustrated having a lower body portion  211   a  and an upper body portion  211   b . The connector  211  preferably has a threaded portion  213  that is matingly threaded for connection to a threaded bore  201  of an engine cooling system component, such as the pipe  200  (or other structure to which the device  10  is mounted as shown in  FIG. 1 ). The connector  211  has a chamber  214  in which sealing means comprising a first sealing member  215  is disposed, the first sealing member  215 , according to a preferred embodiment, comprising a cross-slit valve, having an opening  215   a . As shown in  FIGS. 11 and 12 , in the exploded views, the first sealing member is illustrated being configured as a cross-slit valve  215 , and preferably, the sealing means may further include a second sealing member  216 . As discussed herein, alternately, the sealing members  215 ,  216  may be provided as a single member. The second sealing member  216  has an opening  216   a  therein. According to a preferred embodiment, the second sealing member  216  seals against the flange of the removable cap member  212 . According to the preferred embodiment, the upper body portion  211   b  has threads  250  that connect with threads  251  of the lower body portion  211   a  to secure the upper body portion  211   b  to the lower body portion  211   a . The upper body portion retaining flange  252  holds the sealing members  215 ,  216  against the upper ridge  253  of the lower body portion  211   a.    
         [0053]    The cap member  212  preferably has a bore  226  therein which preferably is threaded with mating threads  227  that engage the threaded end  401  of the anode  400  ( FIG. 12 ) to hold the anode  400  in engagement with the cap member  212 . The anode  400  may be pre-threaded, or alternately, the anode threads  401  may be provided by turning an unthreaded anode into the threaded bore  226  of the cap member  212 . Alternate embodiments may be provided where the cap member  212  is not used. 
         [0054]    The connector  211  preferably has a connecting means for providing a removable connection between the connector  211  and the cap member  212 . The connecting means provides a connection to secure the cap member  212  on the connector  211  and permits removal of the cap member  212  from the connector  211  as needed or desired to replace, install, maintain or inspect the anode  400 , or maintain the structure to which the device  210  is installed, such as, for example, a pipe  200  of the engine system ( FIG. 1 ). 
         [0055]    According to the embodiment illustrated in  FIGS. 10-12 , the connecting means is shown comprising a press-fit connection mechanism. A preferred embodiment of the press-fit connection mechanism comprises a plurality of bearings  233  which are disposed in the side wall  211   c  of the upper body portion  211   b  of the connector  211 . The bearings  233  are shown disposed in a location adjacent the side wall  231  of the cap member  212 , and preferably, the bearings  233  are located so that the annular groove  232 , which, in the preferred embodiment has camming edges  232   a ,  232   b , engages the bearings  233  to move the bearings  233  into engagement with the collar  235 . The bearings  233  are provided to capture the cap member  212  to make a releasable connection between the cap member  212  and the connector  211 , so that the cap member  212  is held on the connector  211 . According to a preferred embodiment, the side wall  211   e  of the connector upper body portion  211   b  preferably has a plurality of bores  234  disposed therein. The bores  234  preferably are disposed in a circumferential arrangement, and preferably are spaced apart. The bores  234  are sized to accommodate the bearings  233 . As shown in  FIG. 10 , the bearings  233  occupy the bores  234 , and a bearing  233  moves within a bore  234  to provide the releasing and securing of the cap member  212  and connector  211 . The annular collar  235  provided on the connector upper body portion  211   b  preferably includes an annular ridge  236  disposed for engagement with the bearings  233  when the cap member  212  is removed or installed on the connector  211 . A spring  237  is provided to bias the collar in an upward direction. The spring  237  according to a preferred embodiment, is disposed on an annular ridge  240  of the first connector  211  upper body portion  211   b , and located between the lower wall  241  of the collar annular ridge  236 . The spring  237  preferably is annularly disposed about the upper body portion  211   b . According to a preferred configuration, the collar  235  is biased by the spring  237  in a direction toward the head  230  of the cap member  212 . Retaining means, such as, for example, the ring  242  shown disposed in an outer annular groove  239  of the collar  235 , is provided to retain the collar  235  on the connector  211  when the cap member  212  is removed from the connector  211 . The ring  242  provides a stop for the collar annular flange  236 , and prevents further upward movement of the collar  235  beyond the connector upper body portion  211   b.    
         [0056]    The device  210  preferably is used with a zinc anode  400 . According to a preferred method, the device  210  may be supplied in one or more components, and may be supplied with an anode, such as a zinc anode, or may be supplied separately from the anodes. According to a preferred embodiment, the anode  400  is secured to the cap member  212 . Preferably, this is accomplished by threading the anode  400  onto the cap member  212  by engaging the anode threads  401  with the cap member threads  227 . If the installation involves a replacement, then a degraded anode which is carried in the cap member  212  is removed from the cap member  212  (preferably, by unscrewing it), and a new anode installed. 
         [0057]    The connector  211  may be installed on a structure, such as, for example a pipe  200 , as is shown and described herein in connection with the embodiments illustrated in  FIGS. 1-9 . 
         [0058]    Referring to  FIGS. 13-14 , an alternate embodiment of a connection mechanism  510  for connecting the anode on the device is illustrated with an upper body portion  511   b  having a connector comprising clips  530 ,  531 . The clips  530 ,  531  preferably are constructed from a resilient material. According to one preferred embodiment, the clips are constructed from spring steel or other suitable wire. The wire clips  530 ,  531  are shown attached to the upper body portion  511   b  at their ends  530   a ,  530   b , and  531   a ,  531   b . One preferred attachment mechanism is shown comprising bores  534 ,  535 ,  536 ,  537 , into which the ends of the wire clips  530   a ,  530   b , and  531   a ,  531   b , respectively, are inserted and held. Although not shown, the ends of the wire clips  530   a ,  530   b , and  531   a ,  531   b  may be secured to the upper body portion by pins, welds, screws or other suitable means. According to some embodiments, the wire clip ends  530   a ,  530   b , and  531   a ,  531   b  are secured by a friction fit in the respective bores  534 ,  535 ,  536 ,  537 . The upper body portion  511   b  or the depth of the bores  534 ,  535 ,  536 ,  537  may be sufficient to secure the wire ends  530   a ,  530   b , and  531   a ,  531   b , and alternately, the depth of the bores may be sufficient to hold screws to connect the upper body portion  511   b  with another element of the connector, such as, for example the middle body portion (see  11   c  of  FIGS. 1-5 ). According to one embodiment, bores  538 ,  539  may be provided in the upper body portion  511  so that screws may be used to connect the upper body portion  511   b  to another component of the connector, such as, for example, the connecting portion  11   c . The upper body portion  511   b  may be used in place of the upper body portion  11   b , and may be connected with the connecting portion  11   e , and connected together with the lower body portion  11   a . The bores  538 ,  539 , and the bores,  534 ,  535 ,  536 ,  537  may receive fasteners, such as, for example screws, to connect with the connecting portion  11   c . Alternate arrangements of the bores, or additional bores, may be provided in the components as required for alignment or connection. 
         [0059]    As shown in  FIGS. 13 and 14 , the anode  500  has a groove  501  around its circumference, and when the anode  500  engages the clips  530 ,  531 , the clips  530 ,  531  separate relative to one another and spring outward, and, as the anode  500  is lowered in the device, when the groove  501  is aligned with the wire clips  530 ,  531 , the clips  530 ,  531  spring inwardly to engage the anode groove  501 . The anode  500  thereby is held on the connector (such as for example, the connector  10  shown and described herein, but fitted with the upper body portion  511   b ). Removal of the anode  500  is accomplished by raising the anode  500  from the connector and disengaging the groove  501  from the wire clips  530 ,  531 . The wire clips  530 ,  531  are moved outwardly from the groove  501  by lifting the anode  500 , and the anode  500  is removed by lifting it out of the device. According to a preferred embodiment, the groove  501  preferably is an annular groove. As illustrated in  FIGS. 13 and 14 , according to one preferred embodiment, the groove  501  may have a first wall that is substantially vertical, such as, for example, wall  501   a  in the embodiment illustrated in  FIGS. 13 and 14 , and one or more walls that are angular in relation to the vertical wall  501   a , such as, for example, the two angular walls  501   b  and  501   c . According to an alternate embodiment (not shown) the anode groove may be non-continuous, and, according to another alternate embodiment, anode embodiments may be provided with a camming surface leading to the groove. 
         [0060]    The anode  500  (as with other anodes shown and described herein) may have a feature to facilitate grasping and pulling, such as, for example, a pull or D-ring, a head, pins or the cap  512 , illustrated in  FIGS. 13-14 , including any of those features as shown and described herein, or any other suitable handle or gripping member. Alternately, the anode  500  may be cylindrical (or provided without a pull) and a tool (such as, pliers, etc.) may be to remove the anode. The wire clips  530 ,  531 , although shown and described in connection with the embodiment illustrated in  FIGS. 13-14 , may be utilized in conjunction with the other connectors disclosed and shown herein to removably retain the anode on a connector. 
         [0061]    An alternate embodiment of an anode  600  is shown in  FIG. 15  having a body  601  with a bore  602  provided therein. The bore  602 , as shown according to a preferred embodiment, is disposed within the body  601 , and the body  601  has a lower portion  601   a  provided below the bore  602 . The anode bore includes a cover  603  provided at the top of the anode  600 . The cover  603  may be constructed from any suitable material, and, according to a preferred embodiment, may be made from, glass, crystal or plastic, such as an acrylic. According to one preferred embodiment, the cover  603  is composed of a mineral crystal. Preferably, the cover is clear to permit viewing, and an indicator means for indicating a condition is provided so that when water reaches an indicator, the indicator provides a detectible response. According to a preferred embodiment the detectible response involves the indicator exhibiting a visual change. According to a preferred embodiment, the indicator means for indicating a condition is shown comprising a water detection pad  604  is provided at the top of the bore  602  and preferably within the bore  602 . The indicator detection pad  604  may be attached to the preferred clear cover  603  and preferably is visible and can be viewed through the cover  603 . The lower body portion  601   a  may be eroded or consumed during use of the anode  600  in customary operating conditions within the environments in which the anode  600  may be used, such as, for example, marine engine cooling systems and other applications where anode plugs and/or anodes are employed. The anode  600  preferably is utilized as a sacrificial anode, and when the lower portion  601   a  is consumed, the lower end of the bore  602  is exposed and the bore  602  communicates with liquid or fluid of the cooling system environment. The liquid or fluid travels through the bore  602  and reaches the indicator detection pad  604 . The detection pad  604 , which is a commercially available component, changes color when water reaches it, and therefore, the color change may be observable through the window or cover  603 . Accordingly, when the color change is observed, then the anode  600  may be replaced with another anode  600 . The anode  600  may be used with the connectors shown and described herein. The cover  603  may be attached to the anode body  601  with the use of any suitable connecting mechanism, and, for example, preferably, is sealed. An adhesive may be used to secure the cover  603  to the anode body  601 . Alternately, while not shown, according to some preferred embodiments, the cover  603  may be secured in a groove or channel, and/or a sealant, o-ring or gasket may be used to prevent or minimize water from passing from the bore  602  or cover  603  outside of the anode  600 . Referring to  FIG. 16 , another alternate embodiment of an anode  700  is constructed like the anode  600 , with an indicator means including an indicator  704  (which may be the detection pad  604 ). The anode  700  is shown having a lower channel or annular groove  750 , an o-ring  751  disposed in the lower groove  750 , a cover  703  disposed to seal against the o-ring  751 , and a retainer clip or ring  760 . The O-ring preferably is made from any suitable material, including an elastomeric material. The cover  703 , according to a preferred embodiment, may be any suitable cover, including a watch crystal, and the indicator  704 , which may be a detection pad (like the pad  604 ), is adhered on the inside of the crystal cover  703 . Preferably, the retainer clip or ring  760  is seated in an upper groove  770  and holds the crystal cover  703  in place against the o-ring  751  to prevent water from leaking out from the opening  709  covered with the crystal cover  703 . Preferably, the covers or portions of the covers are clear to provide viewing of the indicator. The opening  709  communicates with the anode body channel or bore of the anode body (like the bore  602  described above in connection with the anode  600 ). The bore of the anode  700  is shown enclosed and is bordered by at least a portion of the anode body (like the lower body portion  601   a  of anode  600 ). The body bore or body channel has the top opening  709  covered with the cover  703  to provide a window through which the indicator is viewable. The cover  703  seals the first opening  709  of the channel or bore and the lower body portion of the anode that borders the body channel or bore encloses the lower or second opening of the body bore or channel, to close the lower opening of the bore when the anode lower body portion is present, and to provide an opening into the body channel or bore when the lower portion is not present so as to permit fluid communication into the body bore or channel. When at least a portion of the anode body that borders the body bore or channel is eroded (e.g., by galvanic corrosion), then the body bore or channel is provided with an opening for communicating with the cooling fluid in the structure on which the anode plug and anode are installed. 
         [0062]    These and other advantages may be obtained through the use of the inventive apparatus and methods disclosed herein. While the invention has been described with reference to specific embodiments, the description is illustrative and is not to be construed as limiting the scope of the invention. For example, although the anode plug devices  10 ,  110 ,  210 ,  510  are described in connection with a marine engine, the anode plug devices may be used for applications requiring anodic contact where an anode must be maintained or replaced, such as, for example, pipelines, storage tanks, and other applications. In addition, although not shown in  FIGS. 1 ,  2  and  10 , the cap member  12  may be provided with a post and a handle or arms, such as, for example, as shown in connection with the embodiments of  FIGS. 2   a ,  8  and  9 . In addition, the cap member  12  (and  212 ,  512 ) and anode  100  may be integrally provided so that the anode  100  has a cap member  12  (or  212 ,  512 ). Optionally, the cap member  12 ,  212  or  512  may be separately provided, and the anode  100  may secure to the cap member  12  or  212 ,  512 , such as, for example, with mating threads provided on the anode and cap member. According to the invention, the anode may be provided with pins or other element or elements that may be used to facilitate rotating the anode relative to the connector. Although a cap  12 ,  212 ,  512  is shown, the cap member may be excluded, and the anode used without the cap, or with elements provided on the anode for facilitating rotation of the anode. Alternately, the means for removably coupling the anode with the means for connecting the device to a structure may comprise a connection mechanism that secures the anode with the connector without the drawbacks associated with threads. According to alternate embodiments, the connector may be constructed with a connecting mechanism that permits ease of connection and disconnection of the anode from the device, and embodiments may be constructed without the spring  24  that closes the valve  15 . For example, one preferred alternate embodiment may be provided with a sealing element (e.g., the first sealing element or valve  15 , the second sealing element  16 , or both) to seal against the anode when the anode is present in the device. According to another embodiment the sealing element is a valve that expands to seal against the anode, and to contract to close the opening when the anode is not present (e.g., is removed or degrades). Alternate embodiments provide a device for rapid disconnect of an anode from a system using the connectors shown and described herein. For example, according to some embodiments, the device may provide for rapid disconnect of the anode, including embodiments where the cross-slit valve is not provided, but where a sealing element is provided (such as, for example, a sealing element like the second sealing element  16 ) to provide a seal against the anode body when the anode, or anode portion is present to engage the seal. Embodiments of the invention also may provide a rapid disconnect feature for connecting and disconnecting an anode from an anode plug, as illustrated and described herein, but without the sealing elements. A device part may be installed on the system, and another device part may hold the anode and connect to the installed device part. In addition although reference is made to zinc and zinc alloys, the anode may be constructed from other types of metals in alloys with or as a substitute for zinc. Exemplary embodiments are shown and described herein. In addition to the aforementioned, various modifications and changes may occur to those skilled in the art without departing from the spirit and scope of the invention described herein and as defined by the appended claims.

Technology Category: c