Fastener and cap assembly

Abstract

A fastener assembly comprising a fastener body having a tool-engaging drive portion with a fastener surface coating, a threaded fastening portion configured to mate with a corresponding threaded element, and a fastener end face with a bore defined by an inner bore surface, and comprising a cap having a retaining protrusion with an outer retaining surface configured to be received and retained on the fastener end face via an interference fit between the outer retaining surface of the retaining protrusion of the cap and the inner bore surface of the bore of the fastener body, and the cap having a cap end face having a decorative surface with properties different from the properties of the fastener surface coating.

Description

FASTENER AND CAP ASSEMBLYTECHNICAL FIELD

[0001] The present disclosure relates to fasteners, including lug bolts, lug nuts and other coupling members, and more particularly, to fastener and fastener cap assemblies.BACKGROUND ART

[0002] Wheel nuts and wheel bolts are commonly used to attach wheels to axle hub assemblies of automobiles and other vehicles. Such fasteners can have a hexagonal head pattern found on conventional nuts and bolts to which a conventional drive tool such as a wrench may be used to drive the fastener or in the case of locking fasteners may instead have a unique key pattern that is intended to thwart theft by requiring the use of a special security tool having a key pattern that matches the fastener's key pattern. There are also various fastener applications wherein decorative features are desired. Such applications include, but are not limited to, automotive wheel fasteners such as lug bolts and lug nuts. To provide a decorative effect, the exposed head portions of such fasteners are sometimes fitted with a cap having an attractive surface finish, such as chrome plating, PVD coating, and the like.BRIEF SUMMARY

[0003] With parenthetical reference to corresponding parts, portions, or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present disclosure provides a fastener assembly (15, 115, 215, 315) comprising: a fastener body (16, 116. 216, 316) orientated about a central axis (x-x); the fastener body having a tool-engaging drive portion (18, 118, 218, 318) to which a driving torque may be applied; the drive portion of the fastener body having a fastener surface coating (22 A, 122 A, 221 A, 321A); the fastener body having a threaded fastening portion (19, 119, 219, 319) configured and arranged to mate with a corresponding threaded element; the fastener body having a fastener end face (20, 120, 220. 320) and a bore (33. 133, 233, 333) in the fastener end face defined by an inner bore surface (31, 129, 229, 331); the inner bore surface orientated about a central axis and having an inner bore diameter (31D, 129D, 229D, 331D); a cap (40, 140, 240, 340, 440, 540, 640); the cap having a retaining protrusion (41, 141, 241, 341, 441. 541, 641) having an outer retaining surface (45. 145, 245, 345) orientated about the central axis and an outer retaining diameter (45D, 145D, 245D, 345D); the cap having a cap end face (42, 142, 242, 342, 442, 542, 642); the bore in the fastener end face of the fastener configured to receive the retaining protrusion of the cap such that the cap is retained on the fastener endface; and the fastener surface coating of the drive portion of the fastener body having a body coating standard electrode potential and the cap end face of the cap having a cap standard electrode potential that is greater than the body coating standard electrode potential; whereby the cap end face of the cap acts as a galvanic cathode and the fastener surface coating of the drive portion of the fastener body acts as a galvanic anode and the fastener surface coating of the drive portion of the fastener body provides passive cathodic protection against corrosion of the cap end face of the cap.

[0004] The fastener surface coating of the drive portion of the fastener body may be applied over a base material (22B, 122B, 221B, 321B) of the drive portion of the fastener body. The fastener surface coating of the drive portion of the fastener body may comprise one or more layers and may have a thickness of between about 5 microns and 75 microns. The fastener surface coating of the drive portion of the fastener body may comprise a plating or a paint. The fastener surface coating of the drive portion of the fastener body may have a coefficient of friction between about 0.01 and about 0.05. The base material of the drive portion of the fastener body may have a fastener base standard electrode potential that is greater than the body coating standard electrode potential, whereby the base material of the drive portion of the fastener body acts as a galvanic cathode and the fastener surface coating of the drive portion of the fastener body acts as a galvanic anode and the fastener surface coating of the drive portion of the fastener body provides passive cathodic protection against corrosion of the base material of the drive portion of the fastener body. The base material may be a carbon steel or an alloy steel.

[0005] The bore in the fastener end face of the fastener may be configured to receive the retaining protrusion of the cap such that the cap is retained on the fastener end face via an interference fit between the outer retaining surface of the retaining protrusion of the cap and the inner bore surface of the bore of the fastener body. The outer retaining surface of the retaining protrusion of the cap may comprise a knurled surface. The outer retaining diameter of the outer retaining surface of the retaining protrusion of the cap may be equal to or greater than the inner bore diameter of the inner bore surface of the fastener body. The cap end face may be planar (42, 142. 242, 342), concave (542). or convex (442). The cap end face may comprise a decorative surface finish and the decorative surface finish may be selected from a group consisting of a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, and an engraving in the cap end face.

[0006] The drive portion of the fastener body may comprise a hexagonal surface (22, 122) to which a driving torque may be applied. The drive portion of the fastener body may comprise a plurality of circumferentially spaced longitudinally extending key-receiving grooves (250, 350) arranged in a lock pattern to which a driving torque may be applied.

[0007] The threaded fastening portion of the fastener body may comprise an internally threaded nut portion (32. 332) or an externally threaded bolt portion (132, 232).

[0008] In another aspect, a fastener assembly is provided comprising: a fastener body (16, 1 16, 216, 316) orientated about a central axis (x-x); the fastener body having a tool -engaging drive portion (18, 118, 218, 318) to which a driving torque may be applied; the drive portion of the fastener body having a fastener surface (22, 122, 221, 321); the fastener body having a threaded fastening portion (19. 119. 219, 319) configured and arranged to mate with a corresponding threaded element; the fastener body having a fastener end face (20, 120, 220, 320) and a bore (33, 133, 233, 333) in the fastener end face defined by an inner bore surface (31, 129, 229, 331); the inner bore surface orientated about a central axis and having an inner bore diameter (3 ID, 129D, 229D. 33 ID); a cap (40, 140, 240, 340, 440, 540, 640); the cap having a retaining protrusion (41, 141. 241, 341, 441, 541. 641) having an outer retaining surface (45, 145, 245, 345) orientated about the central axis and an outer retaining diameter (45D, 145D, 245D, 345D); the bore in the fastener end face of the fastener configured to receive the retaining protrusion of the cap such that the cap is retained on the fastener end face via an interference fit between the outer retaining surface of the retaining protrusion of the cap and the inner bore surface of the bore of the fastener body; the cap having a cap end face (42, 142, 242, 342, 442, 542, 642); the cap end face having a decorative surface; the decorative surface of the cap end face being different from the fastener surface of the drive portion of the fastener body; the decorative surface of the cap end face having an average roughness (Ra) of between about 20 micro-inches and 250 micro-inches, having a maximum roughness depth (Rmax) of between about 100 micro-inches and 1,500 micro-inches and having a gloss of greater than 50 gloss units (GU) and a gloss greater than the gloss of the fastener surface of the drive portion of the fastener body.

[0009] The decorative surface of the cap end face may be selected from a group consisting of a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving in the cap end face, an etching in the cap end face, and a stamp in the cap end face.

[0010] The outer retaining surface of the retaining protrusion of the cap may comprise a knurled surface. The outer retaining diameter of the outer retaining surface of the retaining protrusion of the cap may be equal to or greater than the inner bore diameter of the inner bore surface of the fastener body. The cap end face may be planar (42, 142, 242, 342), concave (542), or convex (442).

[0011] The fastener surface of the drive portion of the fastener body may comprise a coating (22 A, 122 A. 221 A, 321 A). The coating of the drive portion of the fastener body may have a body coating standard electrode potential and the cap end face of the cap may have a cap standard electrode potential that is greater than the body coating standard electrode potential; whereby the cap end face of the cap acts as a galvanic cathode and the fastener surface coating of the drive portion of the fastener body acts as a galvanic anode and the fastener surface coating of the drive portion of the fastener body provides passive cathodic protection against corrosion of the cap end face of the cap. The drive portion of the fastener body may comprise a hexagonal surface (22, 122) to which a driving torque may be applied or a plurality of circumferentially spaced longitudinally extending key-receiving grooves (250. 350) arranged in a lock pattern to which a driving torque may be applied.

[0012] The fastener assembly set forth in claim 1, wherein the threaded fastening portion of the fastener body comprises an internally threaded nut portion or an externally threaded bolt portionBRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings are incorporated herein as part of the specification. The drawings described herein illustrate embodiments of the presently disclosed subject matter and are illustrative of selected principles and teachings of the present disclosure. However, the drawings do not illustrate all possible implementations of the presently disclosed subject matter and are not intended to limit the scope of the present disclosure in any way.

[0014] FIG. 1 is a perspective view of a first embodiment fastener and cap assembly.

[0015] FIG. 2 is an exploded view of the fastener and cap assembly shown in FIG. 1.

[0016] FIG. 3 is a right side perspective view of the cap shown in FIG. 2.

[0017] FIG. 4 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 1.

[0018] FIG. 4A is an enlarged longitudinal vertical sectional view of the fastener shown in FIG. 4, taken within the indicated circle of FIG. 4.

[0019] FIG. 5 is a longitudinal vertical sectional view' of the fastener and cap assembly shown in FIG. 2.

[0020] FIG. 6 is a perspective view of a second embodiment fastener and cap assembly.

[0021] FIG. 7 is an exploded view of the fastener and cap assembly shown in FIG. 6.

[0022] FIG. 8 is a left side perspective view of the cap shown in FIG. 7.

[0023] FIG. 9 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 6.

[0024] FIG. 9A is an enlarged longitudinal vertical sectional view of the fastener shown in FIG. 9, taken within the indicated circle of FIG. 9.

[0025] FIG. 10 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 7.

[0026] FIG. 11 is a perspective view of a third embodiment fastener and cap assembly.

[0027] FIG. 12 is an exploded view of the fastener and cap assembly shown in FIG. 11.

[0028] FIG. 13 is a left side perspective view of the cap shown in FIG. 12.

[0029] FIG. 14 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 11.

[0030] FIG. 14A is an enlarged longitudinal vertical sectional view of the fastener shown in FIG. 14, taken within the indicated circle of FIG. 14.

[0031] FIG. 15 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 12.

[0032] FIG. 16 is a perspective view of a fourth embodiment fastener and cap assembly.

[0033] FIG. 17 is an exploded view of the fastener and cap assembly shown in FIG. 16.

[0034] FIG. 18 is a left side perspective view of the cap shown in FIG. 17.

[0035] FIG. 19 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 16.

[0036] FIG. 19A is an enlarged longitudinal vertical sectional view of the fastener shown in FIG. 19, taken within the indicated circle of FIG. 19.

[0037] FIG. 20 is a longitudinal vertical sectional view of the fastener and cap assembly shown in FIG. 17.

[0038] FIG. 21 A is a perspective view of a fifth embodiment cap.

[0039] FIG. 21B is a side plan view of the cap shown in FIG. 21A.

[0040] FIG. 22A is a perspective view' of a sixth embodiment cap.

[0041] FIG. 22B is a side plan view of the cap shown in FIG. 22A.

[0042] FIG. 22C is a vertical sectional view- of the cap shown in FIG. 22B.

[0043] FIG. 23A is a perspective view of a seventh embodiment cap.

[0044] FIG. 23B is a side plan view of the cap shown in FIG. 23A.

[0045] FIG. 23C is a vertical sectional view of the cap shown in FIG. 23B.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0046] At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed descnption is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., crosshatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms "horizontal", "vertical", "left", "right", "up" and "down", as well as adjectival and adverbial derivatives thereof (e.g., "horizontally", "rightwardly". "upwardly", etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms "inwardly" and "outwardly" generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

[0047] It is to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments. Hence, specific dimensions, directions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

[0048] It is to be appreciated that the present teaching is by way of example only, not by limitation. The concepts herein are not limited to use or application with a specific system or method. Thus, although the instrumentalities described herein are for the convenience of explanation, shown and described with respect to exemplary embodiments, it will be appreciated that the principles herein may be applied equally in other types of systems and methods involving fasteners.

[0049] Where they are used herein, the terms “first,” “second,” and so forth, do not necessarily denote any ordinal, sequential or priority relation, but are simply used todistinguish one element or set of elements more clearly from another element or set of elements, unless specified otherwise.

[0050] Turning now to the drawing figures, an improved fastener assembly is provided, a first nut-type fastener example embodiment of which is general indicated at 15 in FIGS. 1-5. As show n, fastener assembly 15 generally comprises fastener body 16 and cap 40.

[0051] As shown, in this embodiment fastener body 16 generally comprises tool-engaging portion 18 having inner cap retaining bore 33 at the left end and fastening portion 19 having inner threaded bore 32 at the right end. As shown in FIGS. 4, 4A and 5, fastener body has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly-facing vertical annular end surface 20, leftwardly and outwardly-facing frusto- conical surface 21. outwardly -facing horizontal hexagonal surface 22, leftwardly and outwardly-facing frusto-conical surface 23, outwardly-facing horizontal cylindrical surface 24, rightwardly and outwardly -facing frusto-conical surface 25, rightw-ardly-facing vertical annular stepped end surface 26, inwardly-facing horizontal cylindrical surface 27, leftwardly and inwardly-facing frusto-conical surface 28, inwardly-facing horizontal cylindrical surface 29. rightwardly and inwardly-facing frusto-conical surface 30. inwardly-facing horizontal cylindrical surface 31, and leftwardly and outwardly-facing frusto-conical surface 32. Inner bore 32 is thereby defined by surfaces 26 and 27 and inner bore 33 is thereby defined by surfaces 31 and 32. Tool-engaging portion 18 is thereby defined by hexagonal surface 22, which has a generally hexagonal configuration when viewed from end face 20 and that is configured to be received in a corresponding hex socket, tool, or drive surface of a drive tool (not shown). Although exterior surface 22 of tool-engaging portion 18 is show n as having a hexagonal cross-section, other cross-sections, shapes, or contours could also be used, such as without limitation square or octagonal.

[0052] Threaded fastening portion 19 of fastener body 16 includes bore 32 having internal surface 27 that is internally threaded over a portion or all of its length. Thus, fastening portion 19 of fastener body 16 has threads for engaging a work piece (not shown) on which fastener 15 is to be mounted. For example, nut fastener body 16 may be installed in a wheel having a recess hole formed as a relatively deep cylindrical well. The wheel hole has an annular recess entrance and a wheel stud or post in the wheel hole, and fastener body 16 and fastening portion 19 are sized and installed such that the interior threads of inner surface 27 of bore 32 engage the corresponding exterior threads of the wheel stud in the wheel hole. Accordingly, if the fastener is a nut-style fastener (see the fastener embodiments of FIGS. 1-5 and 16-20), the threads will be internally formed on a bore extending inside the fastenerbody. If the fastener is a bolt-style fastener (see the fastener embodiments of FIGS. 6-15), the threads will be externally formed on the outside of a shank portion of the fastener body as further described below.

[0053] As shown, in this embodiment cap 40 generally comprises cap head 39 and retaining protrusion 41. As shown in FIGS. 4 and 5, cap 40 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly -facing vertical circular end surface 42, outwardly -facing horizontal cylindrical surface 43, rightwardly- facing vertical annular surface 44, outwardly-facing horizontal cylindrical surface 45, and rightwardly-facing vertical circular end surface 46. Retaining protrusion 41 is thereby defined by surfaces 44, 45 and 46. Cap head 39 is thereby defined by surfaces 42 and 43.

[0054] In this embodiment surface 45 of cap 40 is a knurled surface and bore 33 in fastener end face 20 of fastener body 16 is configured and sized to receive retaining protrusion 41 of cap 40 such that cap 40 is retained on fastener end face 20 via an interference fit betw een outer knurled retaining surface 45 of retaining protrusion 41 of cap 40 and inner bore surface 31 of bore 33 of fastener body 16. As shown, outer retaining diameter 45D of outer knurled retaining surface 45 of retaining protrusion 41 of cap 40 is substantially equal to inner bore diameter 3 ID of inner bore surface 31 of fastener body 16. Outer peripheral surface 43 of cap head 39 has diameter 43D that is greater than diameter 3 ID of bore 33 in fastener body 16 such that annular surface 44 of cap 40 rests against end surface 20 of fastener body 16.

[0055] At least drive portion 18 of fastener body 16 has an applied specially configured performance coating 22A. The outer surface of coating 22A defines outer surface 22 and coating 22A is applied to base material 22B of drive portion 18. In an embodiment, fastener coating 22 A of drive portion 18 of fastener body 16 has a body coating standard electrode potential that is less than the standard electrode potential (SEP) of end face 42 of cap 40, as measured for example in accordance with ASTM G215-17. For example, and without limitation, fastener coating 22A may be a zinc aluminum coating such as a zinc flake coating produced by applying a zinc flake dispersion to base 22B of fastener body 16 with the addition of aluminum flakes in a suitable medium. Under the influence of heat (curing), a bonding amongst the flakes and also between the flakes and base 22B is generated, thus forming an inorganic fastener coating 22A sufficiently electrically conducting to ensure cathodic protection. Coating 22A may or may not contain hexavalent chromium. Coating 22A may be applied and tested in accordance with ISO 16426. and in particular ISO 16426:2018. In this embodiment, cap end face 42 of cap 40 acts as a galvanic cathode and fastener coating 22A of drive portion 18 of fastener body 16 acts as a galvanic anode andfastener coating 22A of drive portion 18 of fastener body 16 provides passive cathodic protection against corrosion of cap end face 42 of cap 40. Fastener coating 22A of drive portion 18 of fastener body 16 is more anodic than cap end face 42 of cap 40 and fastener coating 22A of drive portion 18 of fastener body 16 provides passive sacrificial galvanic cathodic protection against corrosion of cap end face 42 of cap 40, pursuant to ISO 10683 for example.

[0056] In this embodiment, coating 22A of drive portion 18 of fastener body 16 may comprise one or more layers. In this embodiment, coating 22A of drive portion 18 of fastener body 16 has a thickness of between about 5 microns and 75 microns, may in some embodiments have a thickness of between about 5 microns and 40 microns, and may in further embodiments have a thickness of between about 6 microns and 20 microns, measured following the ASTM B659-90 Standard Guide for Measuring Thickness of Metallic and Inorganic Coatings. Coating 22A may comprise a plating or a paint. In this embodiment, coating 22A may have a coefficient of friction between about 0.01 and about 0.5, may in some embodiments have a coefficient of friction between about 0.08 and about 0.3, and may in further embodiments have a coefficient of friction between about 0.1 and about 0.25, measured and tested in accordance with ISO 16047. In some embodiments, coating 22A of drive portion 18 may be salt spray corrosion resistant to ISO standard 9227.

[0057] Base material 22B of drive portion 18 of fastener body 16 also has a standard electrode potential that is greater than the standard electrode potential of coating 22A to drive portion 18 of fastener body 16. In this embodiment, base material 22B of drive portion 18 of body 16 also acts as a galvanic cathode and fastener coating 22A of drive portion 18 of fastener body 16 acts as a galvanic anode and fastener coating 22A of drive portion 18 of fastener body 16 provides passive cathodic protection against corrosion of base material 22B of the drive portion 18 of body 16. Fastener coating 22A of drive portion 18 of the fastener body 16 is more anodic than base material 22B of drive portion 18 of the fastener body 16 and fastener coating 22A of drive portion 18 of fastener body 16 provides passive galvanic cathodic protection against corrosion of base material 22B of drive portion 18 of the fastener body 16. For example, and without limitation, in this embodiment base material 22B is a carbon steel or an alloy steel.

[0058] Other performance coatings or finishes may be used as alternatives, including for example and without limitation a zinc coating, a zinc nickel coating, a dual -layered chrome- free coating having an inorganic zinc-rich base coat and an aluminum-rich organic topcoat, and other zinc aluminum coatings.

[0059] Cap end face 42 has a decorative surface that is different and distinct from outer surface 22 of coating 22A of drive portion 18 of fastener body 16. In this embodiment, end face 42 of cap 40 comprises a metal alloy and in particular a zinc and aluminum organic finish. Other finishes may be used as an alternative. As other examples, the decorative surface finish of end face 42 may comprise an a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving, and a decorative design. Thus, cap end face 42 may be decorative by virtue of having a decorative color, material, coating, finish, engraving or design thereon.

[0060] As used herein, the term “decorative” refers to the fact that the cap 40 has a different surface finish than the fastener body 16. The cap 40 can be made “decorative” in any suitable fashion, such as by virtue of having a decorative color, material, or a coating thereon. Stainless steel would be one example of a material that imparts a decorative effect. Chrome plating and PVD coating (Physical Vapor Deposition) are two examples of coatings that may be used. Polymeric or other organic coatings could also be used. Alternative decorative effects could be provided by distinctive surface finishes, surface configurations, surface relief patterns, or applied design markings.

[0061] In this embodiment, the decorative surface of end face 42 has an average roughness (Ra) of between about 20 micro-inches and 300 micro-inches, may in some embodiments have an Ra between about 30 micro-inches and 250 micro-inches, and may in further embodiments have an Ra between about 20 micro-inches and 200 micro-inches, measured following ASTM B46.1 Surface Texture. In this embodiment, the decorative surface of end face 42 has a maximum roughness depth (Rmax) of between about 100 micro-inches and 1,500 micro-inches, may in some embodiments have a Rmax between about 150 microinches and 1,250 micro-inches, and may in further embodiments have a Rmax between about 200 micro-inches and 1,000 micro-inches, measured following ASTM B46. 1 Surface Texture. In addition, or as an alternative, the decorative surface of end face 42 may have a gloss of greater than 50 gloss units (GU) and a gloss greater than the gloss of drive portion 18A of fastener body 16, measured and tested in accordance with ISO 2813. and in particular ISO 2813:2014. In some embodiments, the decorative surface of end face 42 may have a high gloss of greater than 70 gloss units (GU). In other embodiments, the decorative surface of end face 42 may have a gloss of less than 50 gloss units (GU).

[0062] In this embodiment, cap end face 42 is planar. However, the end face of the cap may have a non-planar configuration, including without limitation a domed shape as shownin FIGS. 21A and 21B, a concave shape as shown in FIGS. 22A, 22B and 22C, a frusto- conical shape, and a pyramid shape, by way of example only.

[0063] Referring now to FIGS. 6-10, a bolt-type fastener example embodiment of an improved fastener assembly is general indicated at 115 in FIGS. 6-10. As shown, fastener assembly 115 generally comprises fastener body 116, cap 140, and conical seat washer 160. Fastener assembly 115 has most of the features of fastener assembly 15 described in connection with FIGS. 1-5. The major difference between fastener assembly 115 and fastener assembly 15 is that fastener assembly 1 15 has bolt-type fastener body 116 rather than nut type fastener body 16. Bolt fastener body 116 includes shank 132 that is externally threaded over a portion or all of its length and is installed in a wheel that has at least one hole with threads corresponding to the threads of shank 132 of fastening portion 119.

[0064] As shown, in this embodiment fastener body 116 generally comprises tool-engaging portion 118 having inner cap retaining bore 133 at the left end and fastening portion 119 having threaded shank 132 at the right end. As shown in FIGS. 9, 9A and 10, fastener body 116 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly-facing vertical tapered inner bore end surface 130. inwardly -facing horizontal cylindrical surface 129, leftwardly-facing vertical annular end surface 120, leftwardly and outwardly-facing frusto-conical surface 121, outwardly-facing horizontal hexagonal surface 122, leftwardly -facing vertical annular surface 123, outwardly -facing horizontal cylindrical surface 124. rightwardly -facing vertical annular surface 125, outwardly-facing horizontal cylindrical surface 126, outwardly-facing horizontal cylindrical surface 127, and rightwardly-facing vertical circular end surface 128. Tool-engaging portion 118 is thereby defined by hexagonal surface 122 configured to be received in a corresponding hex socket, tool, or drive surface of a drive tool.

[0065] Threaded fastening portion 119 of fastener body 116 includes shank 132 having external surface 127 that is externally threaded over a portion or all of its length. Thus, fastening portion 119 of fastener body 116 has threads for engaging a w ork piece on which fastener 115 is to be mounted.

[0066] Washer 160 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly-facing vertical annular end surface 161, leftwardly and inwardly -facing frusto-conical surface 162, inwardly -facing horizontal cylindrical surface 163, and rightwardly and outw ardly -facing frusto-conical surface 164. Washer 160 is placed over left end 126 of shank 132 such that leftwardly-facing annular face 161 of washer 160 abuts against and contacts rightwardly-facing annular surface 125 of fastener body 116.

[0067] As shown, in this embodiment cap 140 generally comprises cap head 139 and retaining protrusion 141. As shown in FIGS. 9 and 10, cap 140 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly -facing vertical circular end surface 142, outwardly -facing horizontal cylindrical surface 143, rightwardly- facing vertical annular surface 144, outwardly -facing horizontal cylindrical surface 145, and right war dly -facing vertical circular end surface 146. Retaining protrusion 141 is thereby defined by surfaces 144. 145 and 146. Cap head 139 is thereby defined by surfaces 142 and 143.

[0068] In this embodiment surface 145 of cap 140 is a knurled surface and bore 133 in fastener end face 120 of fastener body 116 is configured and sized to receive retaining protrusion 141 of cap 140 such that cap 140 is retained on fastener end face 120 via an interference fit between outer knurled retaining surface 145 of retaining protrusion 141 of cap 140 and inner bore surface 129 of bore 133 of fastener body 116. As show n, outer retaining diameter 145D of outer knurled retaining surface 145 of retaining protrusion 141 of cap 140 is substantially equal to inner bore diameter 129D of inner bore surface 129 of fastener body 116. Outer peripheral surface 143 of cap head 139 has diameter 143D that is greater than diameter 129D of bore 133 in fastener body 116 such that annular surface 144 of cap 140 rests against end surface 120 of fastener body 116.

[0069] At least drive portion 118 of fastener body 16 has an applied specially configured performance coating 122A. The outer surface of coating 122 A defines outer surface 122 and coating 122A is applied to base material 122B of drive portion 118. In an embodiment, fastener coating 122 A of drive portion 118 of fastener body 116 has a body coating standard electrode potential that is less than the standard electrode potential (SEP) of end face 142 of cap 140, as measured for example in accordance with ASTM G215-17. For example, and without limitation, fastener coating 122 A may be a zinc flake coating produced by applying a zinc flake dispersion to base 122B of fastener body 116 with the addition of aluminum flakes in a suitable medium. Under the influence of heat (curing), a bonding amongst the flakes and also between the flakes and base 122B is generated, thus forming an inorganic fastener coating 122A sufficiently electrically conducting to ensure cathodic protection. Coating 122A may or may not contain hexavalent chromium. The coating may be applied and tested in accordance with ISO 16426, and in particular ISO 16426:2018. In this embodiment, cap end face 142 of cap 140 acts as a galvanic cathode and fastener coating 122A of drive portion 118 of fastener body 116 acts as a galvanic anode and fastener coating 122A of drive portionface 142 of cap 140. Fastener coating 122A of drive portion 118 of fastener body 116 is more anodic than cap end face 142 of cap 140 and fastener coating 122 A of drive portion 118 of fastener body 1 16 provides passive galvanic cathodic protection against corrosion of cap end face 142 of cap 140.

[0070] In this embodiment, coating 122A of drive portion 118 of fastener body 116 may comprise one or more layers. In this embodiment, coating 122A of drive portion 118 of fastener body 116 has a thickness of between about 5 microns and 75 microns, may in some embodiments have a thickness of between about 5 microns and 40 microns, and may in further embodiments have a thickness of between about 6 microns and 20 microns, measured following the ASTM B659-90 Standard Guide for Measuring Thickness of Metallic and Inorganic Coatings. The coating may comprise a plating or a paint. In this embodiment, coating 122A may have a coefficient of friction between about 0.01 and about 0.5, may in some embodiments have a coefficient of friction between about 0.08 and about 0.3, and may in further embodiments have a coefficient of friction betw een about 0.1 and about 0.25, measured and tested in accordance with ISO 16047. In some embodiments, coating 122A of drive portion 118 may be salt spray corrosion resistant to ISO standard 9227.

[0071] Base material 122B of drive portion 118 of fastener body 116 also has a standard electrode potential that is greater than the standard electrode potential of coating 122A. In this embodiment, base material 122B of drive portion 118 of body 116 also acts as a galvanic cathode and fastener coating 122 A of drive portion 118 of fastener body 116 acts as a galvanic anode and fastener coating 122 A of drive portion 118 of fastener body 116 provides passive cathodic protection against corrosion of base material 122B of the drive portion 118 of body 116. Fastener coating 122 A of drive portion 118 of the fastener body 116 is more anodic than base material 122B of drive portion 118 of the fastener body 116 and fastener coating 122A of drive portion 1 18 of fastener body 116 provides passive galvanic sacrificial cathodic protection against corrosion of base material 122B of drive portion 118 of the fastener body 116. For example, and without limitation, in this embodiment base material 122B is a carbon steel or an alloy steel.

[0072] Other performance coatings or finishes may be used as alternatives, including for example and without limitation a zinc coating, a zinc nickel coating, a dual-layered chrome- free coating having an inorganic zinc-rich base coat and an aluminum-rich organic topcoat, and other zinc aluminum coatings.

[0073] Cap end face 142 has a decorative surface finish that is different and distinct from the surface finish of outer hex surface 122 of fastener body 116. In this embodiment, endface 142 of cap 140 comprises a metal alloy and in particular a zinc and aluminum organic finish. Other finishes may be used as an alternative. As other examples, the decorative surface finish of end face 142 may comprise an a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving, and a decorative design. Thus, cap end face 142 may be decorative by virtue of having a decorative color, material, coating, finish, engraving or design thereon.

[0074] In this embodiment, the decorative surface of end face 142 has an average roughness (Ra) of between about 20 micro-inches and 300 micro-inches, may in some embodiments have an Ra between about 30 micro-inches and 250 micro-inches, and may in further embodiments have an Ra between about 20 micro-inches and 200 micro-inches, measured following ASTM B46.1 Surface Texture. In this embodiment, the decorative surface of end face 142 has a maximum roughness depth (Rmax) of between about 100 micro-inches and 1,500 micro-inches, may in some embodiments have a Rmax between about 150 micro-inches and 1,250 micro-inches, and may in further embodiments have a Rmax between about 200 micro-inches and 1,000 micro-inches, measured following ASTM B46.1 Surface Texture. In addition, or as an alternative, the decorative surface of end face 142 may have a gloss of greater than 50 gloss units (GU) and a gloss greater than the gloss of drive surface 122 of fastener body 116, measured and tested in accordance with ISO 2813, and in particular ISO 2813:2014. In some embodiments, the decorative surface of end face 142 may have a high gloss of greater than 70 gloss units (GU). In other embodiments, the decorative surface of end face 142 may have a gloss of less than 50 gloss units (GU).

[0075] Referring now to FIGS. 11-15, a second bolt-ty pe fastener example embodiment of an improved fastener assembly is general indicated at 215 in FIGS. 11-15. As shown, fastener assembly 215 generally comprises fastener body 216, cap 240 and conical seat washer 260. Fastener assembly 215 has most of the features of fastener assembly 115 described in connection with FIGS. 6-10. The major difference between fastener assembly 215 and fastener assembly 115 is that fastener assembly 215 has key-type tool engaging portion 218 of fastener body 216 rather than hex-type tool engaging portion 118 of fastener body 116. Key portion 218 of fastener body 216 comprises a key-receiving pattern that may be implemented as a set of circumferentially arranged lock pattern grooves 250. Lock pattern configurations that use formations of other grooves may also be used. As can be seen, lock pattern grooves 250 are visible on the annular left end face 220 of fastener body 216. As further described herein, in order to impart lock pattern uniqueness, lock pattern grooves 250may be patterned or configured in any suitable alternative manner, such as by employing a selected number of grooves and / or by varying other features thereof, such as the spacing between grooves and / or the width, length, depth, profile or other configuration or feature thereof.

[0076] As show n, in this embodiment fastener body 216 generally comprises tool-engaging portion 218 having inner cap retaining bore 233 at the left end and fastening portion 219 having threaded shank 232 at the right end. As shown in FIGS. 14. 14A and 15, fastener body 216 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly-facing vertical tapered inner bore end surface 230, inwardly -facing horizontal cylindrical surface 229, leftwardly-facing vertical annular end surface 220, outwardly-facing horizontal cylindrical key pattern surface 221, outwardly-facing horizontal cylindrical surface 222, leftwardly-facing vertical annular surface 223, outwardly -facing horizontal cylindrical surface 224, rightwardly-facing vertical annular surface 225, outwardly-facing horizontal cylindrical surface 226, outwardly-facing horizontal cylindrical surface 227, and rightwardly-facing vertical circular end surface 228.

[0077] Tool-engaging portion 218 is thereby defined by key pattern surface 221 that extends inwardly from left end face 220 of body 216 and has a specially configured profile to which a drive torque is applied. This profile comprises a key-receiving pattern that is defined by a set of circumferentially spaced externally facing longitudinally extending key-receiving grooves 250 arranged in a lock pattern to which the drive torque is applied. As can be seen, lock pattern grooves 250 are accessible on the annular left front face 220 of tool engaging portion 218 and are configured so that a corresponding drive key tool (not shown) may be used to engage lock pattern grooves 250. The drive key includes a drive shaft formed with a key pattern that is implemented as a set of circumferentially arranged key pattern lobes that are configured and arranged to engage lock pattern grooves 250 in face 220 when the drive shaft is properly aligned and placed around the left end of fastener body 216. Thus, a key having a matching set of key pattern lobes is used to engage lock pattern grooves 250 to actuate fastener 215 about axis x-x. The security key is configured to fit onto end face 220 of fastener body 216 to engage the lock pattern and rotate bolt fastener 215. Other tools either will not fit over the end of fastener body 216 or will not be able to properly engage and rotate fastener 215 when it is installed at its intended design installation torque.

[0078] As with fastener assembly 115, threaded fastening portion 219 of fastener body 216 includes shank 232 having external surface 227 that is externally threaded over a portion orall of its length. Thus, fastening portion 219 of fastener body 216 has threads for engaging a work piece on which fastener 215 is to be mounted.

[0079] Washer 260 has the same configuration as washer 160 and is placed over left end 226 of shank 232 such that leftwardly-facing annular face 261 of washer 260 abuts against and contacts rightwar dly -facing annular surface 225 of fastener body 216.

[0080] Cap 240 has the same configuration as cap 140 and generally comprises cap head239 and retaining protrusion 241. Surface 245 of cap 240 is a knurled surface and bore 233 in fastener end face 220 of fastener body 216 is configured and sized to receive retaining protrusion 241 of cap 240 such that cap 240 is retained on fastener end face 220 via an interference fit between outer knurled retaining surface 245 of retaining protrusion 241 of cap240 and inner bore surface 229 of bore 233 of fastener body 216 and such that annular surface 244 of cap 240 rests against end surface 220 of fastener body 216.

[0081] In this embodiment, outer peripheral surface 243 of cap head 239 has diameter 243D that is greater than diameter 229D of bore 233 in fastener body 216 such that annular surface 244 of cap 240 rests against end surface 220 of fastener body 216. In addition, outer peripheral surface 243 of cap head 239 has diameter 243D that is less than inner diameter 250D at the innermost radial depths of grooves 250 of key pattern surface 221 in fastener body 216 such that the key pattern of tool engaging portion 218 of fastener body 216 is accessible to a corresponding drive key without the need to remove cap 240 from bore 233.

[0082] At least drive portion 218 of fastener body 216 has an applied specially configured performance coating 221 A. The outer surface of coating 221 A defines outer surface 221 and coating 221A is applied to base material 221B of drive portion 218. In an embodiment, fastener coating 221 A of drive portion 218 of fastener body 216 has a body coating standard electrode potential that is less than the standard electrode potential (SEP) of end face 242 of cap 240, as measured for example in accordance with ASTM G215-17. For example, and without limitation, fastener coating 221 A may be a zinc flake coating produced by applying a zinc flake dispersion to base 22 IB of fastener body 216 with the addition of aluminum flakes in a suitable medium. Under the influence of heat (curing), a bonding amongst the flakes and also between the flakes and base 22 IB is generated, thus forming an inorganic fastener coating 221 A sufficiently electrically conducting to ensure cathodic protection. Coating 221 A may or may not contain hexavalent chromium. The coating may be applied and tested in accordance with ISO 16426, and in particular ISO 16426:2018. In this embodiment, cap end face 242 of cap 240 acts as a galvanic cathode and fastener coating 221 A of drive portion 218 of fastener body 216 acts as a galvanic anode and fastener coating 221 A of drive portion218 of fastener body 216 provides passive cathodic protection against corrosion of cap end face 242 of cap 240. Fastener coating 221A of drive portion 218 of fastener body 216 is more anodic than cap end face 242 of cap 240 and fastener coating 221 A of drive portion 218 of fastener body 216 provides passive galvanic cathodic protection against corrosion of cap end face 242 of cap 240.

[0083] In this embodiment, coating 221A of drive portion 218 of fastener body 216 may comprise one or more layers. In this embodiment, coating 221 A of drive portion 218 of fastener body 216 has a thickness of between about 5 microns and 75 microns, may in some embodiments have a thickness of between about 5 microns and 40 microns, and may in further embodiments have a thickness of between about 6 microns and 20 microns, measured following the ASTM B659-90 Standard Guide for Measuring Thickness of Metallic and Inorganic Coatings. The coating may comprise a plating or a paint. In this embodiment, coating 221A may have a coefficient of friction between about 0.01 and about 0.5, may in some embodiments have a coefficient of friction between about 0.08 and about 0.3, and may in further embodiments have a coefficient of friction between about 0.1 and about 0.25, measured and tested in accordance with ISO 16047. In some embodiments, coating 221A of drive portion 218 may be salt spray corrosion resistant to ISO standard 9227.

[0084] Base material 221B of drive portion 218 of fastener body 216 also has a standard electrode potential that is greater than the standard electrode potential of coating 221 A. In this embodiment, base material 221B of drive portion 218 of body 216 also acts as a galvanic cathode and fastener coating 221 A of drive portion 218 of fastener body 216 acts as a galvanic anode and fastener coating 221 A of drive portion 218 of fastener body 216 provides passive cathodic protection against corrosion of base material 221B of the drive portion 218 of body 216. Fastener coating 221 A of drive portion 218 of the fastener body 216 is more anodic than base material 221B of drive portion 218 of the fastener body 216 and fastener coating 221 A of drive portion 218 of fastener body 216 provides passive sacrificial galvanic cathodic protection against corrosion of base material 221B of drive portion 218 of the fastener body 216. For example, and without limitation, in this embodiment base material 22 IB is a carbon steel or an alloy steel.

[0085] Other performance coatings or finishes may be used as alternatives, including for example and without limitation a zinc coating, a zinc nickel coating, a dual-layered chrome- free coating having an inorganic zinc-rich base coat and an aluminum-rich organic topcoat, and other zinc aluminum coatings.

[0086] Cap end face 242 has a decorative surface finish that is different and distinct from the surface finish of outer surface 221 of fastener body 216. In this embodiment, end face 242 of cap 240 comprises a metal alloy and in particular a zinc and aluminum organic finish. Other finishes may be used as an alternative. As other examples, the decorative surface finish of end face 242 may comprise an a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving, and a decorative design. Thus, cap end face 242 may be decorative by virtue of having a decorative color, material, coating, finish, engraving or design thereon.

[0087] In this embodiment, the decorative surface of end face 242 has an average roughness (Ra) of between about 20 micro-inches and 300 micro-inches, may in some embodiments have an Ra between about 30 micro-inches and 250 micro-inches, and may in further embodiments have an Ra between about 20 micro-inches and 200 micro-inches, measured following ASTM B46.1 Surface Texture. In this embodiment, the decorative surface of end face 242 has a maximum roughness depth (Rmax) of between about 100 micro-inches and 1.500 micro-inches, may in some embodiments have a Rmax between about 150 micro-inches and 1,250 micro-inches, and may in further embodiments have a Rmax between about 200 micro-inches and 1,000 micro-inches, measured following ASTM B46. 1 Surface Texture. In addition, or as an alternative, the decorative surface of end face 242 may have a gloss of greater than 50 gloss units (GU) and a gloss greater than the gloss of drive portion 218A of fastener body 216, measured and tested in accordance with ISO 2813, and in particular ISO 2813:2014. In some embodiments, the decorative surface of end face 242 may have a high gloss of greater than 70 gloss units (GU). In other embodiments, the decorative surface of end face 242 may have a gloss of less than 50 gloss units (GU).

[0088] Referring now to FIGS. 16-20, a second nut-type fastener example embodiment of an improved fastener assembly is general indicated at 315 in FIGS. 16-20. As shown, fastener assembly 315 generally comprises fastener body 316 and cap 340. Fastener assembly 315 has most of the features of fastener assembly 15 described in connection with FIGS. 1-5. The major difference between fastener assembly 315 and fastener assembly 15 is that fastener assembly 315 has key -type tool engaging portion 318 of fastener body 316 rather than hex-type tool engaging portion 18 of fastener body 16. Key portion 318 of fastener body 316 comprises a key-receiving pattern that may be implemented as a set of circumferentially arranged lock pattern grooves or notches 350. Lock pattern configurations that use formations of other notches, recesses or grooves may also be used. As can be seen.lock pattern notches 350 are visible on the annular left end face 320 of fastener body 316. As further described herein, in order to impart lock pattern uniqueness, lock pattern notches 350 may be patterned or configured in any suitable alternative manner, such as by employing a selected number of notches and / or by varying other features thereof, such as the spacing between notches and / or the width, length, depth, profile or other configuration or feature thereof.

[0089] As shown, in this embodiment fastener body 316 generally comprises tool-engaging portion 318 having inner cap retaining bore 333 at the left end and fastening portion 319 having inner threaded bore 332 at the right end. As shown in FIGS. 19, 19A and 20, fastener body 316 has a generally cylindrical configuration elongated along axis x-x and is generally bounded by leftwardly-facing vertical annular end surface 320, outwardly-facing horizontal cylindrical key pattern surface 321, outwardly-facing horizontal cylindrical surface 322, rightwardly and outwardly -facing frusto-conical surface 323A, outwardly-facing horizontal cylindrical surface 323B, leftwardly and outwardly-facing frusto-conical surface 323C, outwardly-facing horizontal cylindrical surface 324, rightwardly and outwardly-facing frusto- conical surface 325. rightwardly-facing vertical annular stepped end surface 326, inwardly- facing horizontal cylindrical surface 327, leftwardly and inwardly -facing frusto-conical surface 328, inwardly-facing horizontal cylindrical surface 329, rightwardly and inwardly- facing frusto-conical surface 330, inwardly-facing horizontal cylindrical surface 331, and leftwardly and outwardly-facing frusto-conical surface 332. Inner bore 332 is thereby defined by surfaces 326 and 327 and inner bore 333 is thereby defined by surfaces 331 and 321.

[0090] Tool-engaging portion 318 is thereby defined by key pattern surface 321 that extends inwardly from left end face 320 of body 316 and has a specially configured profile to which a drive torque may be applied. This profile comprises a key-receiving pattern that is defined by a set of circumferentially spaced externally facing longitudinally extending keyreceiving notches 550 arranged in a lock pattern to which the drive torque is applied. As can be seen, lock pattern notches 350 are accessible on the annular left front face 320 of tool engaging portion 318 and are configured so that a corresponding drive key tool is used to engage lock pattern notches 350. The drive key includes a drive shaft formed with a key pattern that implemented as a set of circumferentially arranged key pattern lobes that are configured and arranged to engage lock pattern notches 350 in face 320 when the drive shaft is properly aligned and placed around the left end of fastener body 316. Thus, a key having a matching set of key pattern lobes is used to engage lock pattern notches 350 to actuatefastener 315 about axis x-x. The security key is configured to fit onto end face 320 of fastener body 316 to engage the lock pattern and rotate nut fastener 315. Other tools either will not fit over the end of fastener body 316 or will not be able to properly engage and rotate fastener 315 when it is installed at its intended design installation torque.

[0091] As with fastener assembly 15, threaded fastening portion 319 of fastener body 316 includes bore 332 having internal surface 327 that is internally threaded over a portion or all of its length. Thus, fastening portion 319 of fastener body 316 has threads for engaging a work piece on which fastener 315 is to be mounted.

[0092] Cap 340 has the same configuration as cap 40 and generally comprises cap head339 and retaining protrusion 341. Surface 345 of cap 340 is a knurled surface and bore 333 in fastener end face 320 of fastener body 316 is configured and sized to receive retaining protrusion 341 of cap 340 such that cap 340 is retained on fastener end face 320 via an interference fit between outer knurled retaining surface 345 of retaining protrusion 341 of cap340 and inner bore surface 331 of bore 333 of fastener body 316 and such that annular surface 344 of cap 340 rests against end surface 320 of fastener body 316.

[0093] In this embodiment, outer peripheral surface 343 of cap head 339 has diameter 343D that is greater than diameter 33 ID of bore 333 in fastener body 316 such that annular surface 344 of cap 340 rests against end surface 320 of fastener body 316. In addition, outer peripheral surface 343 of cap head 339 has diameter 343D that is less than inner diameter 350D at the innermost radial depths of notches 350 of key pattern surface 321 in fastener body 316 such that the key pattern of tool engaging portion 318 of fastener body 316 is accessible to a corresponding drive key without the need to remove cap 340 from bore 333.

[0094] At least drive portion 318 of fastener body 316 has an applied specially configured performance coating 321 A. The outer surface of coating 321 A defines outer surface 321 and coating 321 A is applied to base material 321B of drive portion 318. In an embodiment, fastener coating 321A of drive portion 318 of fastener body 316 has a body coating standard electrode potential that is less than the standard electrode potential (SEP) of end face 342 of cap 340, as measured for example in accordance with ASTM G215-17. For example, and without limitation, fastener coating 321 A may be a zinc flake coating produced by applying a zinc flake dispersion to base 32 IB of fastener body 316 with the addition of aluminum flakes in a suitable medium. Under the influence of heat (curing), a bonding amongst the flakes and also between the flakes and base 321B is generated, thus forming an inorganic fastener coating 321A sufficiently electrically conducting to ensure cathodic protection. Coating 321 A may or may not contain hexavalent chromium. The coating may be applied and testedin accordance with ISO 16426, and in particular ISO 16426:2018. In this embodiment, cap end face 342 of cap 340 acts as a galvanic cathode and fastener coating 321 A of drive portion 318 of fastener body 316 acts as a galvanic anode and fastener coating 321 A of drive portion 318 of fastener body 316 provides passive cathodic protection against corrosion of cap end face 342 of cap 340. Fastener coating 321A of drive portion 318 of fastener body 316 is more anodic than cap end face 342 of cap 340 and fastener coating 321 A of drive portion 318 of fastener body 316 provides passive galvanic cathodic protection against corrosion of cap end face 342 of cap 340.

[0095] In this embodiment, coating 321 A of drive portion 318 of fastener body 316 may comprise one or more layers. In this embodiment, coating 321 A of drive portion 318 of fastener body 316 has a thickness of between about 5 microns and 75 microns, may in some embodiments have a thickness of between about 5 microns and 40 microns, and may in further embodiments have a thickness of between about 6 microns and 20 microns, measured following the ASTM B659-90 Standard Guide for Measuring Thickness of Metallic and Inorganic Coatings. The coating may comprise a plating or a paint. In this embodiment, coating 321A may have a coefficient of friction between about 0.01 and about 0.5, may in some embodiments have a coefficient of friction between about 0.08 and about 0.3, and may in further embodiments have a coefficient of friction between about 0.1 and about 0.25, measured and tested in accordance with ISO 16047. In some embodiments, coating 321A of drive portion 318 may be salt spray corrosion resistant to ISO standard 9227.

[0096] Base material 32 IB of drive portion 318 of fastener body 316 also has a standard electrode potential that is greater than the standard electrode potential of coating 321A. In this embodiment, base material 321B of drive portion 318 of body 316 also acts as a galvanic cathode and fastener coating 321 A of drive portion 318 of fastener body 316 acts as a galvanic anode and fastener coating 321 A of drive portion 318 of fastener body 316 provides passive cathodic protection against corrosion of base material 321 B of the drive portion 318 of body 316. Fastener coating 321A of drive portion 318 of the fastener body 316 is more anodic than base material 321B of drive portion 318 of the fastener body 316 and fastener coating 321 A of drive portion 318 of fastener body 316 provides passive sacrificial galvanic cathodic protection against corrosion of base material 321B of drive portion 318 of the fastener body 316. For example, and without limitation, in this embodiment base material 321B is a carbon steel or an alloy steel.

[0097] Other performance coatings or finishes may be used as alternatives, including for example and without limitation a zinc coating, a zinc nickel coating, a dual-layered chrome-free coating having an inorganic zinc-rich base coat and an aluminum-rich organic topcoat, and other zinc aluminum coatings.

[0098] Cap end face 342 has a decorative surface finish that is different and distinct from the surface finish of outer surface 321 of fastener body 316. In this embodiment, end face 342 of cap 340 comprises a metal alloy and in particular a zinc and aluminum organic finish. Other finishes may be used as an alternative. As other examples, the decorative surface finish of end face 342 may comprise an a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving, and a decorative design. Thus, cap end face 342 may be decorative by virtue of having a decorative color, material, coating, finish, engraving or design thereon.

[0099] In this embodiment, the decorative surface of end face 342 has an average roughness (Ra) of between about 20 micro-inches and 300 micro-inches, may in some embodiments have an Ra between about 30 micro-inches and 250 micro-inches, and may in further embodiments have an Ra between about 20 micro-inches and 200 micro-inches, measured following ASTM B46.1 Surface Texture. In this embodiment, the decorative surface of end face 342 has a maximum roughness depth (Rmax) of between about 100 micro-inches and 1,500 micro-inches, may in some embodiments have a Rmax between about 150 micro-inches and 1,250 micro-inches, and may in further embodiments have a Rmax between about 200 micro-inches and 1,000 micro-inches, measured following ASTM B46.1 Surface Texture. In addition, or as an alternative, the decorative surface of end face 342 may have a gloss of greater than 50 gloss units (GU) and a gloss greater than the gloss of drive surface 321 of fastener body 316, measured and tested in accordance with ISO 2813, and in particular ISO 2813:2014. In some embodiments, the decorative surface of end face 342 may have a high gloss of greater than 70 gloss units (GU). In other embodiments, the decorative surface of end face 342 may have a gloss of less than 50 gloss units (GU).

[0100] Referring now to FIGS. 21A and 21B, an alternative example embodiment of an improved cap is general indicated at 440 in FIGS. 21A and 21B. As shown, in this embodiment cap 440 generally comprises cap head 439 and knurled retaining protrusion 441. As with the other embodiment, knurled retaining protrusion 441 is configured and sized to be received and retained in bore 33, 133, 233 and / or 333 of fastener body 16, 116, 216 and / or 316, respectively. However, as shown, in this embodiment end face 442 of cap 440 has a convex or domed shape.

[0101] Referring now to FIGS. 22A, 22B and 22C, an alternative example embodiment of an improved cap is general indicated at 540 in 22A, 22B and 22C. As shown, in this embodiment cap 540 generally comprises cap head 539 and knurled retaining protrusion 541. As with the other embodiment, knurled retaining protrusion 541 is configured and sized to be received and retained in bore 33, 133, 233 and / or 333 of fastener body 16, 116, 216 and / or 316, respectively. However, as shown, in this embodiment end face 542 of cap 540 has a concave shape.

[0102] Referring now to FIGS. 23A, 23B and 23C, an alternative example embodiment of an improved cap is general indicated at 640 in 23A, 23B and 23C. As shown, in this embodiment cap 640 generally comprises cap head 639 and knurled retaining protrusion 641. As with the other embodiment, knurled retaining protrusion 641 is configured and sized to be received and retained in bore 33, 133, 233 and / or 333 of fastener body 16, 116, 216 and / or 316, respectively. However, as shown, in this embodiment end face 642 of cap 640 has a generally hexagonal hollow half cone shape. The end face of the cap may have other alternative shapes and contours.

[0103] It should be appreciated that certain features of the system, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination. While various embodiments have been described in detail above, it should be understood that they have been presented by w ay of example, and not limitation. It will be apparent to persons skilled in the relevant arts that the disclosed subject matter may be embodied in other specific forms, variations, and modifications without departing from the scope, spirit, or essential characteristics thereof. The embodiments described above are therefore to be considered in all respects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.13506076 1

Claims

CLAIMS1. A fastener assembly comprising: a fastener body orientated about a central axis: said fastener body having a tool-engaging drive portion to which a driving torque may be applied; said drive portion of said fastener body having a fastener surface coating; said fastener body having a threaded fastening portion configured and arranged to mate with a corresponding threaded element; said fastener body having a fastener end face and a bore in said fastener end face defined by an inner bore surface; said inner bore surface orientated about a central axis and having an inner bore diameter; a cap; said cap having a retaining protrusion having an outer retaining surface orientated about said central axis and an outer retaining diameter; said cap having a cap end face; said bore in said fastener end face of said fastener configured to receive said retaining protrusion of said cap such that said cap is retained on said fastener end face; and said fastener surface coating of said drive portion of said fastener body having a body coating standard electrode potential and said cap end face of said cap having a cap standard electrode potential that is greater than said body coating standard electrode potential; whereby said cap end face of said cap acts as a galvanic cathode and said fastener surface coating of said drive portion of said fastener body acts as a galvanic anode and said fastener surface coating of said drive portion of said fastener body provides passive cathodic protection against corrosion of said cap end face of said cap.

2. The fastener assembly set forth in claim 1, wherein said fastener surface coating of said drive portion of said fastener body is applied over a base material of said drive portion of said fastener body.

3. The fastener assembly set forth in claim 2, wherein said fastener surface coating of said drive portion of said fastener body comprises one or more layers and has a thickness of between about 5 microns and 75 microns.

4. The fastener assembly set forth in claim 2, wherein said fastener surface coating of said drive portion of said fastener body comprises a plating or a paint.

5. The fastener assembly set forth in claim 2, wherein said fastener surface coating of said drive portion of said fastener body has a coefficient of friction between about 0.01 and about 0.05.

6. The fastener assembly set forth in claim 2, wherein said base material of said drive portion of said fastener body has a fastener base standard electrode potential that is greater than said body coating standard electrode potential, whereby said base material of said drive portion of said fastener body acts as a galvanic cathode and said fastener surface coating of said drive portion of said fastener body acts as a galvanic anode and said fastener surface coating of said drive portion of said fastener body provides passive cathodic protection against corrosion of said base material of said drive portion of said fastener body.

7. The fastener assembly set forth in claim 1, wherein said bore in said fastener end face of said fastener is configured to receive said retaining protrusion of said cap such that said cap is retained on said fastener end face via an interference fit between said outer retaining surface of said retaining protrusion of said cap and said inner bore surface of said bore of said fastener body.

8. The fastener assembly set forth in claim 7, wherein said outer retaining surface of said retaining protrusion of said cap comprises a knurled surface.

9. The fastener assembly set forth in claim 7, wherein said outer retaining diameter of said outer retaining surface of said retaining protrusion of said cap is equal to or greater than said inner bore diameter of said inner bore surface of said fastener body.

10. The fastener assembly set forth in claim 1, wherein said cap end face is planar, concave, or convex.

11. The fastener assembly set forth in claim 1, wherein said cap end face comprises a decorative surface finish and said decorative surface finish is selected from a group consisting of a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, and an engraving in said cap end face.

12. The fastener assembly set forth in claim 1, wherein said drive portion of said fastener body comprises a hexagonal surface to which a driving torque may be applied or a plurality of circumferentially spaced longitudinally extending key-receiving grooves arranged in a lock pattern to which a driving torque may be applied.

13. The fastener assembly set forth in claim 1. wherein said threaded fastening portion of said fastener body comprises an internally threaded nut portion or an externally threaded bolt portion.

14. A fastener assembly comprising: a fastener body onentated about a central axis; said fastener body having a tool-engaging drive portion to which a driving torque may be applied; said drive portion of said fastener body having a fastener surface; said fastener body having a threaded fastening portion configured and arranged to mate with a corresponding threaded element; said fastener body having a fastener end face and a bore in said fastener end face defined by an inner bore surface; said inner bore surface orientated about a central axis and having an inner bore diameter; a cap; said cap having a retaining protrusion having an outer retaining surface orientated about said central axis and an outer retaining diameter; said bore in said fastener end face of said fastener configured to receive said retaining protrusion of said cap such that said cap is retained on said fastener end face via an interference fit between said outer retaining surface of said retaining protrusion of said cap and said inner bore surface of said bore of said fastener body; said cap having a cap end face; said cap end face having a decorative surface; said decorative surface of said cap end face being different from said fastener surface of said drive portion of said fastener body; said decorative surface of said cap end face having an average roughness (Ra) of between about 20 micro-inches and 250 micro-inches, having a maximum roughness depth (Rmax) of between about 100 micro-inches and 1 ,500 micro-inches, and / or having a gloss ofgreater than 50 gloss units (GU) and a gloss greater than a gloss of said fastener surface of said drive portion of said fastener body.

15. The fastener assembly set forth in claim 14, wherein said decorative surface of said cap end face is selected from a group consisting of a chrome coating, a painted coating, a powder coating, a nickel plating, a metal alloy plating, a vapor deposition coating, a zinc and aluminum organic finish, an anodized coating, an engraving in said cap end face, an etching in said cap end face, and a stamp in said cap end face.

16. The fastener assembly set forth in claim 14, wherein said outer retaining surface of said retaining protrusion of said cap compnses a knurled surface.

17. The fastener assembly set forth in claim 14, wherein said outer retaining diameter of said outer retaining surface of said retaining protrusion of said cap is equal to or greater than said inner bore diameter of said inner bore surface of said fastener body.

18. The fastener assembly set forth in claim 1, wherein said cap end face is planar, concave, or convex.

19. The fastener assembly set forth in claim 1, wherein said fastener surface of said drive portion of said fastener body comprises a coating.

20. The fastener assembly set forth in claim 19, wherein said coating of said fastener surface of said drive portion of said fastener body has a body coating standard electrode potential and said cap end face of said cap has a cap standard electrode potential that is greater than said body coating standard electrode potential; whereby said cap end face of said cap acts as a galvanic cathode and said fastener surface coating of said drive portion of said fastener body acts as a galvanic anode and said fastener surface coating of said drive portion of said fastener body provides passive cathodic protection against corrosion of said cap end face of said cap.

21. The fastener assembly set forth in claim 14, wherein said drive portion of said fastener body comprises a hexagonal surface to which a driving torque may be applied or a plurality of circumferentially spaced longitudinally extending key -receiving grooves arranged in a lock pattern to which a driving torque may be applied.

22. The fastener assembly set forth in claim 1, wherein said threaded fastening portion of said fastener body comprises an internally threaded nut portion or an externally threaded bolt portion.

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