Patent Abstract:
A fastener to removably mount an object in a mounting aperture of a panel is provided. The fastener includes a body having two opposing side members and defining a second aperture configured to accept at least a portion of the object, at least one elastic abutting flange disposed between the fastener body and the mounting aperture, a corrosion resistant coating, and a silencer plating overlying the corrosion resistant coating.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/669,316, filed on Apr. 07, 2005. The disclosure of the above application is incorporated herein by reference. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates generally to resilient clip fasteners and more particularly to a resilient clip fastener that employs a particular surface geometry to secure the body portion of the resilient clip to a structure. The invention also relates to a resilient clip fastener having corrosion-resistant silencer plating.  
       BACKGROUND OF THE INVENTION  
       [0003]     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.  
         [0004]     Many vehicles employ resilient clips to secure various components to the vehicle body. One such application concerns interior panels that mount to the interior of the vehicle such as panels that mount onto the doors of the vehicle. Such panels serve not only to provide occupants with a convenient point to grasp during ingress to and egress from the vehicle, but also provide energy absorption during a crash event.  
         [0005]     It is conventional procedure that the entire panel assembly is installed onto the interior of the vehicle in a single operation. In order to accomplish this assembly task, the panel assembly is typically equipped with numerous fasteners, located around the periphery of the panel assembly as well as at predetermined locations around the interior area of the panel, that are adapted to penetrate through corresponding holes located in the reinforcing sheet metal members of the vehicle interior. For aesthetic reasons, the panel fasteners are typically secured in some fashion to the backside of the panel so that they are not visible from the interior of the vehicle after the panel assembly is installed. Consequently, it is often incumbent upon the line operators to blindly “feel” for the location of the mounting holes with their fingers before pressing the fasteners into the holes from the opposite show-surface side of the panel.  
         [0006]     If misalignments occur between the fasteners and their corresponding mounting holes during this panel-securing operation, some of the fasteners may not be properly seated. Not only do these misalignments reduce the overall security of the panels to the sheet metal, but they also may cause excessive noise or squeaking from movement of the fastener against the sheet metal as forces are transmitted through the vehicle when the vehicle is driven over bumps or other irregularities in the road; such movement generates acoustical vibrations heard as the noise or squeaking. Such noise or squeaking can be annoying to the driver and any passengers in the vehicle.  
         [0007]     Lubrication may be used to prevent the noise; but some lubricants only temporarily reduce friction, and specific types of lubricants are undesirable for use with interior trim. For example, it may not be desirable to use a “wet” lubricant, such as oil or grease, near locations of fabric or leather upholstery since the “wet” lubricant might stain the upholstery. Such staining risk is further aggravated in some installation situations where, for example, a line operator&#39;s view of the fastening components becomes highly limited during panel installation as the fastening components are meshed or connected. While dry lubricating films do not stain the interior, they can be highly moisture sensitive and susceptible to corrosion.  
         [0008]     Accordingly, there remains a need in the art for an improved fastener having a relatively low installation force, a relatively high removal force, and an improved (relative to the present approach and issues described above) tolerance to misalignments in a fastened assembly made through use of the fastener. It is further desirable that the fastener include a dry lubrication feature with improved features to reduce vibration noise, improve wear, and withstand the change of temperature and humidity within the vehicle under the operating conditions of the vehicle. Ideally, the fastener should be inexpensive to manufacture as well as being reliable and simple to install.  
       SUMMARY OF THE INVENTION  
       [0009]     The present invention provides a fastener having at least one metallic abutting flange for slidably and compressively interfacing against the inner surface of a mounting aperture. A dry sulfur-containing lubricant surface of the flange bears against the inner surface, and corrosion suppressant is in chemically reactive contact with the lubricant of the surface. The lubricant surface suppresses acoustic waves generated from vibrating movement of the inner surface against the flange so that the acoustic waves are essentially inaudible to the human ear.  
         [0010]     In one embodiment, the present invention provides a fastener adapted to removably mount an object in a mounting aperture of a panel. The fastener body has two opposing side members and also defines a second aperture configured to accept at least a portion of the object. The fastener body has at least one elastic abutting flange defining an exterior concave portion extending a width of the abutting flange, and the abutting flange is configured to engage an inner surface of the mounting aperture when the fastener is inserted into the mounting aperture. In this embodiment, the elastic abutting flange is disposed between the fastener body and the mounting aperture. A corrosion resistant coating is a part of the fastener and silencer plating overlies the corrosion resistant coating.  
         [0011]     In another embodiment, the present invention provides a U-shaped fastener adapted to be removably mounted within a mounting aperture of a panel. The fastener comprises a body defining a pair of generally parallel members coupled by a curved end member where at least one of the parallel members comprises a first and second pair of finger members configured to slidably accept a coupling flange and to tightly engage the coupling flange to the fastener after the coupling flange is slidably accepted. The fastener also comprises a pair of abutting flanges with each abutting flange of the pair independently defining an exterior concave surface extending a width of the abutting flange and configured to engage an inner surface of the mounting aperture when the fastener is inserted into the mounting aperture. Corrosion resistant coating is disposed on each abutting flange where the exterior surface is-configured to engage the inner surface; and silencer plating overlies the corrosion resistant coating.  
         [0012]     In yet another embodiment, the present invention provides a fastener for removably mounting a coupling flange in a panel aperture. The fastener comprises a base portion and two opposing side walls integrally connected to the base portion and forming a substantially U-shaped body, where each side wall of the two opposing side walls has an outwardly extending top flange member. A pair of elastic abutting flanges are integrally formed with and outwardly extending from the base portion, and a first pair of spaced apart finger members are integrally formed with each top flange member. The fastener has corrosion resistant coating disposed on each abutting flange, and the fastener has silencer plating overlying the corrosion resistant coating. The pair of finger members inwardly extend into the body of the fastener and are configured to grippingly engage the coupling flange.  
         [0013]     In one aspect, the present invention provides a method for attaching a component to a mounting aperture of a structural support so that the component can be optionally removed from the support. The method first affixes a fastener to the component, the fastener having at least one metallic abutting flange that slidably and compressively interfaces against an inner surface of the mounting aperture; the flange has a dry sulfur-containing lubricant surface (for bearing against the inner surface) and corrosion suppressant in chemically reactive contact with the lubricant surface. The method then inserts the fastener within the mounting aperture to compressively bear the abutting flange against the inner surface. The lubricant surface suppresses acoustic waves generated from vibrating movement of the inner surface against the flange so that the acoustic waves are essentially inaudible to the human ear.  
         [0014]     In another aspect, the present invention provides a method for attaching a component to a mounting aperture of a structural support so that the component can be optionally removed from the aperture. The component has at least one metallic abutting flange that slidably and compressively interfaces against an inner surface of the mounting aperture. The method comprises adhering dry sulfur-containing lubricant and corrosion suppressant to an interface surface of the flange such that the corrosion suppressant is in chemically reactive contact with the lubricant, and then inserting the fastener within the mounting aperture to compressively bear the lubricant of the abutting flange against the inner surface. The lubricant is adhered to be sufficient to suppress acoustic waves generated from vibrating movement of the inner surface against the flange so that the acoustic waves are essentially inaudible to the human ear.  
         [0015]     In a preferred embodiment of a fastener, the silencer plating comprises molybdenum disulfide and the corrosion resistant coating comprises zinc. In one embodiment, a fastener is configured for insertion into a mounting aperture with an insertion force less than about 10 pounds, and for removal from the panel aperture with a removal force greater than about 20 pounds.  
         [0016]     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:  
         [0018]      FIG. 1  is a perspective view of a fastener constructed in accordance with the teachings of the present invention;  
         [0019]      FIG. 2  is a lower perspective view of the fastener of  FIG. 1 ;  
         [0020]      FIG. 3   a  is a side view of a portion of the fastener of  FIG. 1  illustrating the spacing of the structures in greater detail;  
         [0021]      FIGS. 3   b  and  3   c  depict cross-sectional views of the fastener depicted in  FIG. 3   a;    
         [0022]      FIG. 4  is a side view of a fastener constructed in accordance with the teachings of a preferred embodiment of the present invention;  
         [0023]      FIG. 5   a  is a top view of a portion of the fastener of  FIG. 1 , illustrating the clip structure in greater detail;  
         [0024]      FIGS. 5   b  and  5   c  depict cross-sectional views of the fastener depicted in  FIG. 5   a;    
         [0025]      FIG. 6  is a lower perspective view of the fastener of  FIG. 1 ;  
         [0026]      FIG. 7  is a bottom view of the fastener of  FIG. 1 ;  
         [0027]      FIG. 8  is a perspective view of the fastener of  FIG. 1 ;  
         [0028]      FIG. 9  is an exploded perspective view showing the fastener being used to mount an interior trim component;  
         [0029]      FIGS. 10   a  and  10   b  show the insertion of the fastener;  
         [0030]      FIG. 11  is a cross-sectional view of the inserted fastener of  FIG. 10   b  with corresponding trim component;  
         [0031]      FIG. 12  is a perspective view of a fastener constructed in accordance with the teachings of a second embodiment of the present invention;  
         [0032]      FIG. 13  is a lower perspective view of the fastener of  FIG. 12 ;  
         [0033]      FIG. 14   a  is a side view of a portion of the fastener of  FIG. 13  illustrating the spacing of the structures in greater detail;  
         [0034]      FIGS. 14   b  and  14   c  depict cross-sectional views of the fastener depicted in  FIG. 14   a;    
         [0035]      FIG. 15   a  is a side view of a portion of the fastener of  FIG. 14   a;    
         [0036]      FIG. 15   b  is a top view of the fastener of  FIG. 15   a;    
         [0037]      FIGS. 15   c  and  15   d  depict cross-sectional side views of the fastener depicted in  FIG. 15   b;    
         [0038]      FIG. 16  is a lower perspective view of the fastener of  FIG. 12 ;  
         [0039]      FIG. 17  is a top view of a portion of the fastener of  FIG. 12 , illustrating the clip structure in greater detail;  
         [0040]      FIG. 18  is a perspective view of the fastener of  FIG. 12 ;  
         [0041]      FIG. 19  is an exploded perspective view showing the fastener of  FIG. 12  being used to mount an interior trim component;  
         [0042]      FIGS. 20   a  and  20   b  show the insertion of the fastener;  
         [0043]      FIG. 21  is a cross-sectional view of the inserted fastener of  FIG. 20   b  with corresponding trim component; and  
         [0044]      FIG. 22  is a cross-sectional view of a coated portion of fastener substrate from a fastener. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0045]     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features  
         [0046]     Referring to  FIGS. 1 through 8 , a generally U-shaped fastener  20  in accordance with the present invention is disclosed. The generally U-shaped fastener  20  is defined by a body portion  22  and a pair of top flanges  24 . Integral with the top flanges  24  are two pair of finger members  26  which are used to couple the generally U-shaped fastener  20  to a mounting flange (shown in  FIG. 11 ). Additionally, the body portion  22  has a pair of abutting flanges  28  which generally lie outside side members  29  and  30  of the body portion  22 . The side members  29  and  30 , which are coupled by a curved bottom member  40  (base portion  40 ), define a pair of apertures  32  and  33 , which allow for the inward compression of the abutting flanges  28 .  
         [0047]     Generally, as shown in  FIG. 2 , each of the abutting flanges  28  is further defined by having three portions. The first portion  36  is defined by a concave exterior engaging surface  50 . The second portion  37 , which acts as a transition to the third portion  38 , is defined by a convex exterior surface. The third portion  38  functions to couple the abutting flange  28  to the base portion  40  of the body portion  22  of the generally U-shaped fastener  20 .  
         [0048]      FIG. 3   a  depicts a first side view (along the axis of curvature for base portion  40 ) of the generally U-shaped fastener  20  of the current invention. Shown is the relationship of the finger members  26  to the abutting flanges  28 , which are formed within the aperture  32 . As best seen in  FIGS. 3   b  and  4 , the tips  42  of the finger members  26  are angled to frictionally engage a flange member  54  of a trim component  60  (see  FIG. 11 ). The A-A cross-sectional view of  FIG. 3   b  (reference from  FIG. 3   a ) and the B-B cross-sectional view of  FIG. 3   c  also show the relationship of the third portions  38  to the base member  40  of the body portion  22  for the fastener.  
         [0049]      FIG. 4  depicts a second side view (in a plane perpendicular to the axis of curvature for base portion  40 ) of the U-shaped fastener  20  and shows the relationship of portions  36 ,  37 , and  38  of the abutting flanges  28  to members  29 ,  30 , and  40  of the body portion  22 . As can be seen, each of the top flanges  24  define a respective upper keyhole slot  49 , and slots  49  allow the movement of the abutting flanges  28  when they are compressed. Further depicted is the angular relationship of the side members  29  and  30  of the body portion with respect to the base  40  and the top flanges  24 . It must be noted that while the finger members  26  are shown, any suitable fastener is usable. This includes but is not limited to a hole, a threaded hole, slots, or flanges.  
         [0050]      FIG. 5   a  depicts a top view of the generally U-shaped fastener  20 . Defined by the side members  29  and  30  is a slot  48  which is used to engage the coupling flange  54  (see  FIGS. 9 and 11 ) of a trim component  60 . The concave exterior surface  50  (see  FIGS. 4 and 5   b ) of the abutting flanges  28  are used to engage sheet metal to hold the fastener in place. Also depicted is the interior surface  52  ( FIG. 5   b ) of the finger members  26 , which engage the surfaces of the coupling flange  54  (see  FIGS. 9 and 11 ). Exterior concave surface  50  comprises silencer plating. The silencer plating is coated upon a corrosion resistant coating that is, in turn, coated onto the fastener substrate of abutting flange  28 . Structural coating detail respective to exterior concave surface  50  is further described in the discussion of  FIG. 22 .  
         [0051]      FIG. 5   b  displays the C-C cross-sectional view of the fastener as referenced in  FIG. 5   a.  Depicted is the relationship of the abutting flanges  28  with the base member  40 . Further, the cross-section details the radius of the exterior concave surface  50 . The radius of the concave surface  50  generally can be from about 3.5 to about 6.0 millimeters and, preferably, about 4.75 millimeters. The center of curvature for the radius R is from about 2 to about 4 millimeters from the top of the fastener and, preferably, about 2.3 millimeters. The D-D cross-sectional view (reference in  FIG. 5   a ) in  FIG. 5   c  of the fastener best details the relationship of the finger members  26  to the top flanges  24  and to the first and second flange members  43  and  44 .  
         [0052]      FIGS. 6 through 8  are depictions of the U-shaped fastener  20  of the current invention with hidden components shown in phantom. Depicted is the relationship of the fastener components with various surfaces of the fastener.  
         [0053]      FIG. 9  depicts the use of the U-shaped fastener  20  of the current invention. Shown is a sheet metal structure  56 , which defines a pair of apertures  58 . The apertures  58  are designed to accept the U-shaped fastener  20  to allow for the mating of a trim component  60  to the sheet metal  56 . The trim component  60  has a pair of flanges  54 , which are inserted into the slot  48  of the U-shaped fastener  20 .  
         [0054]     As best seen in  FIG. 10   a  and  FIG. 10   b,  the U-shaped fastener  20  is inserted into the aperture  58  of the sheet metal structure  56 . As the fastener  20  is depressed into the aperture  58 , the abutting flanges  28  are compressed toward each other and the centerline of the U-shaped fastener  20 . This compression of the abutting flanges  28  continues until the sheet metal  56  of the aperture  58  reaches the second portion  37  of the abutting flanges. At this point, a transition occurs and the sheet metal  56  is allowed to engage ( FIG. 10   b ) with the concave surface  50  of the first portion  36  of the abutting flanges  28 . In this regard, the bottom or minimal extremum of concave curvature for each concave surface  50  of the first portion  36  of each abutting flange  28  rests, in fastened position, against the defining edge of aperture  58  in sheet metal structure  56 .  
         [0055]      FIG. 11  depicts the coupling of the trim component  60  to the U-shaped fastener  20 . Shown is the coupling flange  54  inserted between the finger members  26  of the U-shaped fastener  20 .  
         [0056]     It has been shown that the current fastener  20  is significantly more easily inserted into sheet metal structure  56  than removed from the sheet metal structure  56  once inserted. For example, the fastener as depicted has a required insertion force of about 10 pounds and a removal force of greater than 20 pounds.  
         [0057]     Referring to  FIGS. 12 through 20 , a generally U-shaped fastener  120  in accordance with a second embodiment of the present invention is disclosed. The generally U-shaped fastener  120  is defined by a body portion  122  and a pair of top flanges  124 . Integral with the top flanges  124  are two coupling finger member pair sets: a double pair of first finger members  126  and a double pair of second finger members  127  which are used to couple the generally U-shaped fastener  120  to a mounting flange (shown in  FIG. 21 ). Additionally, the body portion  122  has a pair of abutting flanges  128  which generally lie outside the side members  129  and  130  of the body portion  122 . The side members  129  and  130  define a pair of apertures,  132  and  133 , which allow for the inward compression of the abutting flanges  128 .  
         [0058]     Generally, as shown in  FIG. 13 , each of the abutting flanges  128  is further defined by having three portions. The first portion  136  is defined by a concave exterior engaging surface  150 . The second portion  137 , which acts as a transition to the third portion  138 , is defined by a convex exterior surface. The third portion  138  functions to couple the abutting flange  128  to the base portion  140  of the body  122  of the generally U-shaped fastener  120 .  
         [0059]      FIG. 14   a  depicts a first side view (along the axis of curvature for base portion  140 ) of the generally U-shaped fastener  120  of the second embodiment of the current invention. Shown is the relationship of a first finger member  126  and a second finger member  127  to an abutting flange  128 , which is formed within the aperture  132 . As best seen in the A-A cross-sectional view of  FIG. 14   b  (reference from  FIG. 14   a ) and in  FIG. 15A  (a second side view in a plane perpendicular to the axis of curvature for base portion  140 ), the tips  142  of the first finger members  126  and the tips  143  of the second finger members  127  are angled to frictionally engage a flange member  154  of a trim component  160  (see  FIGS. 19 and 21 ). The angle of the first finger member  126  can be from about 15° to about 25° and, preferably, about 20°, while the angle of the second finger member  127  can be from about 50° to about 60° and, preferably, about 55°. The A-A cross-sectional view of  FIG. 14   b  (reference  FIG. 14   a ) and the B-B cross-sectional view of  FIG. 14  show the relationship of the third portion  138  to the base member  140  of the body portion  122  for the fastener.  
         [0060]      FIG. 15   a  depicts a second side view (in a plane perpendicular to the axis of curvature for base portion  140 ) of the U-shaped fastener  120  and shows the relationship of the abutting flanges  128  to the body portion  122 . As can be seen, each of the top flanges  124  defines an upper keyhole slot  149 , and slots  149  allow the movement of the abutting flanges  128  when they are compressed. Further depicted is the angular relationship of the side members  129  and  130  of the body portion with respect to the base  140  and the top flanges  124 . It must be noted that while the finger members  126  and  127  are shown, any suitable fastener is usable. This includes but is not limited to a hole, a threaded hole, slots, or flanges.  
         [0061]      FIG. 15   b  depicts a top view of the generally U-shaped fastener  120 . Defined by the side members  129  and  130  is a slot  148  which is used to engage the coupling flange  154  (see  FIGS. 19 and 21 ) of a trim component  160 . The concave exterior surface  150  of the abutting flanges  128  are used to engage sheet metal to hold the fastener in place. Also depicted is the interior surface  152  ( FIG. 15   c ) and tips  142  of the first finger members  126  as well as tips  143  of second finger members  127 , which collectively engage the surfaces of the coupling flange  154  (see  FIGS. 19 and 21 ). Exterior concave surface  150  comprises silencer plating. The silencer plating is coated upon a corrosion resistant coating that is, in turn, coated onto the fastener substrate of abutting flange  128 . Structural coating detail respective to exterior concave surface  150  is further described in the discussion of  FIG. 22 .  
         [0062]      FIG. 15   c  displays the C-C cross-sectional view of the fastener as referenced in  FIG. 15   b.  Depicted is the relationship of the abutting flanges  128  with the base member  140 . Further, the cross-section details the radius of the exterior concave surface  150 . The radius of the concave surface  150  generally can be from about 3.5 to about 6.0 millimeters and, preferably, about 4.75 millimeters. The center of curvature for the radius R is from about 2 to about 4 millimeters from the top of the fastener and, preferably, about 2.3 millimeters. The D-D cross-sectional view (reference in  FIG. 15   b ) in  FIG. 5   d  of the fastener best details the relationship of the first finger member  126  to the top flanges  124  and the first and second flange members  143  and  144 .  
         [0063]      FIGS. 16 through 18  are depictions of the U-shaped fastener  120  of the current invention with hidden components shown in phantom. Depicted is the relationship of the fastener components with various surfaces of the fastener.  
         [0064]      FIG. 19  depicts the use of the U-shaped fastener  120  of the current invention. Shown is a sheet metal structure  156 , which defines a pair of apertures  158 . The apertures  158  are designed to accept the U-shaped fastener  120  to allow for the mating of a trim component  160  to the sheet metal  156 . The trim component  160  has a pair of flanges  154 , which are inserted into the slot  148  of the U-shaped fastener  120 .  
         [0065]     As best seen in  FIG. 20   a  and  FIG. 20   b,  the U-shaped fastener  120  is inserted into the aperture  158  of the sheet metal structure  156 . As the fastener  120  is depressed into the aperture  158 , the abutting flanges  128  are compressed toward each other and the centerline of the U-shaped fastener  120 . This compression of the abutting flanges  128  continues until the sheet metal  156  of the aperture  158  reaches the second portion  137  of the abutting flanges. At this point, a transition occurs and the sheet metal  156  is allowed to engage ( FIG. 20   b ) with the concave surface  156  of the first portion  136  of the abutting flanges  128 .  
         [0066]      FIG. 21  depicts the coupling of the trim component  160  to the U-shaped fastener  120 . Shown is the coupling flange  154  inserted between the first and second finger members  126  and  127  of the U-shaped fastener  120 . In this regard, the bottom or minimal extremum of concave curvature for each concave surface  150  of the first portion  136  of each abutting flange  128  rests, in fastened position, against the defining edge of aperture  158  in sheet metal structure  156 .  
         [0067]     It has been shown that the current fastener  120  is significantly easier to insert into sheet metal structure  156  than removed form sheet metal structure  156  once inserted. For example, the fastener as depicted has a required insertion force of about 10 pounds and a removal force of greater than 20 pounds.  
         [0068]     The silencer plating of the present invention reduces friction between the fastener and the sheet metal that causes squeaking or other noise related to vibrations between and/or among the coupled fastener and sheet metal components. In this regard, the silencer plating comprises a film or dry coating on the fastener where the coating (film) is plated onto its respective fastener substrate surface to provide a dry lubrication feature or attribute to the fastener surface that will reduce vibration noise and improve wear characteristics of any sheet metal surface against which the plating slides or vibrates. Examples of such surfaces benefiting from silencer plating are (a) surface  50  ( FIG. 4 ) as deployed against sheet metal structure  56  ( FIG. 11 ) and (b) surface  150  ( FIG. 15C ) as deployed against sheet metal structure  156  ( FIG. 21 ). In preferred embodiments, the plating comprises a sulfur-containing dry lubricant such as, preferably, molybdenum disulfide. Another sulfur-containing dry lubricant for consideration in use is tungsten disulfide.  
         [0069]     Molybdenum disulfide has a structure that allows the MoS 2  particles of the plating to slide past each other and relieve stresses between the underlying fastener and the sheet metal when they slide, even to a small degree, against each other. Without the plating to relieve the stresses, friction between the underlying fastener and the sheet metal generates acoustic vibrations and thereby causes excessive noise. Despite its benefits, use of the molybdenum disulfide is limited because it reacts with oxygen or water in the air to form corrosive products that then can corrode the metal flanges of the fastener. The present invention solves this problem by providing humidity and/or corrosion resistance to the molybdenum disulfide through use of a corrosion suppressant in chemically reactive contact with the lubricant coating. This corrosion suppressant is preferably the corrosion resistant coating further described herein. Furthermore, the use of the corrosion resistant coating provides improved adhesion of the molybdenum disulfide to the fastener. In preferred embodiments, the corrosion resistant coating comprises zinc. In alternative embodiments, the corrosion resistant coating comprises either manganese phosphate or zinc phosphate. Zinc coating is preferred insofar as good salt spray resistance to corrosion is achieved at 72 hours of salt spray exposure. If salt spray resistance is not an issue, manganese phosphate or zinc phosphate can also be used in the corrosion resistant coating. In yet another embodiment, the coating comprises a combination of zinc, manganese phosphate, and/or zinc phosphate.  
         [0070]     The silencer plating and the corrosion resistant coating are applied to any or all of the fastener components, portions, and/or members. The corrosion resistant coating is applied using any suitable metal application technique or combination of techniques, including, but not limited to, immersion plating, chemical conversion, electroless plating, mechanical plating, detonation gun application, plasma arc, vacuum plasma, wire arc, chemical vapor deposition, electron beam evaporation, ion beam assisted deposition, ion implantation, ion plating, physical vapor deposition, sputtering, and vacuum metalizing. The silencer plating is then applied over the corrosion resistant coating using any suitable technique, including, but not limited to, rubbing or burnishing the molybdenum disulfide powder onto the coated substrate; dipping, brushing, or spraying the substrate with a dispersion of molybdenum disulfide in a volative solvent (and then evaporating the solvent); vacuum sputtering; or using a binder material (resin, silicate, phosphate, or ceramic) to adhere the molybdenum disulfide film to the substrate.  
         [0071]     The fastener substrate may optionally be pre-treated before the application of the corrosion resistant coating. For example, in many cases it is desirable to pre-treat the substrate to remove a passivation layer that builds up on the metal substrate upon exposure to oxygen. In various embodiments, pre-treatment involves subjecting the surface to reducing conditions, which renders the substrate surface of the fastener more electrochemically active for receiving the coating. Other pre-treating methods include degreasing of the fastener surfaces before applying the corrosion resistant coating or etching of the corrosion resistant coating to increase the surface tension of the coating before applying the silencer plating. Subsequent treatment steps such as forced-air cooling may also be employed.  
         [0072]     The corrosion resistant coating and the silencer plating are applied at any suitable thickness that does not interfere with the operation or purpose of the fastener (fitting into a mounting hole, for example) and also enables corrosion-protecting efficacy in the silencer plating from chemically-reactive contact between the corrosion resistant coating and the silencer plating. The corrosion resistant coating has a thickness of from at least a monolayer up to about 50 micrometers (μm). The silencer plating has a thickness of from at least a monolayer up to about 50 μm. The thickness of each coating is selected to provide adequate lubrication, promote adhesion of the molybdenum to the corrosion resistant coating, prevent corrosion of the molybdenum via chemical reaction between the corrosion suppressant and the silencer plating, prolong the endurance life of the silencer plating, and minimize noise from vibration of the fastener in its connected position. A preferred thickness for each of the corrosion resistant coating and the silencer plating is from about 1 μm to about 50 μm (more preferably, the silencer plating and corrosion resistant coating each have an independent thickness of from about 5 micrometer to about 20 micrometers). In this regard, chemically-reactive contact (necessary for suppressing long-term corrosion of the fastener abutting flange interface surface) between the silencer plating and the corrosion suppressant is enabled in many embodiments by a relatively thin layer of corrosion resistant coating underlying the relatively thin layer of silencer plating even as lubricity of the silencer plating on the interface surface of the fastener is maximized though an interface surface of high purity molybdenum disulfide. The chemically-reactive contact provides a material continuum enabling migration of ions, electrons, and atoms among the interconnected material system of the fastener substrate abutting flange, the corrosion suppressant, and the silencer plating such that detrimental corrosion of the lubricated surface (the interface surface) of the abutting flange essentially does not occur and so that the fastener continues to provide a “quiet” fastening to the component (panel) to which it is attached.  
         [0073]     In further detail of the fastener substrate coatings,  FIG. 22  shows a cross-sectional view  200  of a coated portion of fastener substrate  258  from a fastener (such as a portion of abutting flange  28  of fastener  20  in the region of exterior concave surface  50  or a portion of abutting flange  128  of fastener  120  in the region of exterior concave surface  150 ). Note that relative thicknesses of substrate  258 , corrosion resistant coating  252 , and silencer plating  254  in  FIG. 22  are not accurate in visual scale, and the coatings are depicted in exaggerated relative thicknesses for purposes of clear description; the actual relative dimensions provide relative thicknesses of corrosion resistant coating  252  and of silencer plating  254  that are very substantially less that those depicted in  FIG. 22  when compared to the thickness of substrate  258 . In cross-sectional view  200 , fastener substrate concave surface  256  interfaces to corrosion resistant coating  252 . Resistant coating  252  has a preferred thickness of from at least a monolayer up to about 50 micrometers (μm). Corrosion resistant coating  252  also interfaces to silencer plating  254 . Silencer plating  254  preferably has a thickness of from at least a monolayer up to about 50 micrometers (μm). More preferably, the silencer plating and corrosion resistant coating each have an independent thickness of from about 5 micrometer to about 20 micrometers.  
         [0074]     Concave surface  250  references coating detail in either exterior concave surface  50  (in abutting flange  28  of fastener  20 ) or exterior concave surface  150  (in abutting flange  128  of fastener  120 ) respective to previously described embodiments. By providing a corrosion-stabilized lubricated interfacing surface made of a material having a low inter-molecular shearing force (a corrosion-stabilized lubricated interfacing surface) for a surface portion of a fastener that facilitates optional removal (detachment) from a component to which it is attached from use of elastic abutting flanges that slidably and compressively interface (via compression and/or torsion spring forces) to the component (such as a panel as described herein) with side movement and/or slippage being highly restricted (but not rigidly restricted) through use of smoothed surface geometry (such as a concave interfacing surface with the interface to the component being positioned at essentially the bottom or minimal extremum of concave curvature as previously described), the fastener attaches to the component with a “quiet” compressive joint in operationally dynamic use of the connected combination of fastener and component (panel) when the fastener is in fastened position. In this regard, when the lubricated surface of the fastener is subjected to limited oscillatory slippage against the surface of the component from vibrations that modify the inertial relative positioning of the component and the fastener (when the fastener is essentially in fastened position), acoustic pressure waves that emanate from rubbing (limited oscillatory slippage) between the interfacing surface of the fastener and the component should be essentially non-audible to the human ear.  
         [0075]     The corrosion resistant coating and the silencer plating are applied over all surfaces of the fastener substrate in one fastener embodiment. A dipping procedure to fully immerse the fastener substrate in each coating (with appropriate drying of the corrosion resistant coating prior to immersion in the silencer plating) is used in one embodiment in providing such a comprehensive coating. In another embodiment, the corrosion resistant coating and the silencer plating are applied only to surfaces of the fastener substrate that interface to other component surfaces. A procedure of masking and spraying is used in one embodiment in providing such a precision-positioned coating to each interface surface of the fastener. In yet another embodiment for coating interface surfaces of the fastener, the corrosion resistant coating and the silencer plating are applied to the general regions of surfaces of the fastener substrate that interface to other component surfaces. A procedure of spraying to a target area on the fastener is used in one embodiment of providing such a regional coating. The thin layer of corrosion resistant coating underlying the thin layer of silencer plating enables chemically-reactive contact between the silencer plating and the corrosion suppressant while maximizing lubricity of the silencer plating on the interface surface of the fastener.  
         [0076]     The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such a discussion, and from the accompanying drawings and claims that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention.

Technology Classification (CPC): 8