Method of manufacturing a corrosion-resistant, headed fastener, such as nail for exterior applications, and manufacturing method

A method for manufacturing a corrosion-resistant, headed fastener, comprising the steps of:

• providing a carbon steel wire pre-coated with a protective, metallic layer having corrosion-resistant properties wherein said protective, metallic layer is not present and is therefore discontinuous at a region defined upon a leading end portion of said pre-coated wire;
• disposing a protective, metallic cap, having corrosion-resistant properties, near said leading end portion of said pre-coated wire;
• and
• simultaneously securing said protective, metallic cap upon said leading end portion of said pre-coated wire, so as to cover said region of said leading end portion of said pre-coated wire at which said protective, metallic layer is discontinuous, and deforming said leading end portion of said pre-coated wire so as to form a fastener from said pre-coated wire which has a shank portion, and a head portion which includes said region at which said protective, metallic layer is discontinuous, such that said protective, metallic cap provides corrosion resistance to said region of said head portion of said fastener at which said protective, metallic layer is discontinuous while said protective, metallic layer provides corrosion resistance to said shank portion of said fastener.

A method of manufacturing a corrosion-resistant headed fastener, comprising the steps of:

• providing a carbon steel wire pre-coated with a protective, metallic layer having corrosion-resistant properties wherein said protective, metallic layer is not present and is therefore discontinuous at a region defined upon a leading end portion of said pre-coated wire;
• disposing a metallic material, having corrosion-resistant properties, near said leading end portion of said pre-coated wire;
• and
• simultaneously severing a portion of said metallic material from a remaining portion of said metallic material, securing said severed portion of said metallic material upon said leading end portion of said pre-coated wire so as to cover said region of said leading end portion of said pre-coated wire at which said protective, metallic layer is discontinuous, and deforming said leading end portion of said pre-coated wire so as to form a fastener from said pre-coated wire which has a shank portion, and a head portion which includes said region at which said protective, metallic layer is discontinuous, such that said severed, secured portion of said metallic material serves as a protective cap which provides corrosion resistance to said region of said head portion of said fastener at which said protective, metallic layer is discontinuous while said protective, metallic layer provides corrosion resistance to said shank portion of said fastener.