Brazing Material Containing A Flux
A wire for use in a brazing or soldering operation is provided. The wire preferably includes a body formed of a metallic material. A flux solution is provided within a channel along at least a portion of the length of the body and a surface of the flux solution is exposed. The body is preferably formed into an annular ring having an inner wall and an opposing outer wall. The flux solution preferably includes a solvent, a polymer dissolved in the solvent, and a powdered flux added to the polymer solution.
1 . A wire for use in a brazing or soldering operation, the wire comprising:
an elongated body of a metallic material;
a channel having an opening formed along a length of the elongated body; and
a flux solution within the channel and along at least a portion of the length of the elongated body with a surface of the flux solution being exposed.
2 . The wire of claim 1 wherein the elongated body is formed into an annular ring having an inner wall and an opposing outer wall.
3 . The wire of claim 1 wherein the flux solution further comprises:
a solvent,
a polymer wherein the polymer is one of a granulated or a beaded polymer and is dissolved in the solvent, and
a powdered flux added to the polymer solution.
4 . The wire of claim 1 wherein the metallic material is selected from a group consisting of nickel, cobalt, copper, gold, aluminum, magnesium, silver, a combination of these metals, and an alloy formed from these metals.
5 . The wire of claim 2 wherein the metallic material in the ring is silver.
6 . The wire of claim 2 wherein the metallic material in the ring is aluminum.
7 . The wire of claim 2 wherein the metallic material in the ring is an alloy made of zinc and aluminum.
8 . The wire of claim 4 wherein the metallic material is a zinc and aluminum alloy.
9 . The wire of claim 3 wherein the solvent is selcected from a group consisting of glycol ether acetates, alcohols, polyols, alkanolamines, aromatic solvents, terpenes, ketones, n-methyl-2-pyrroloidone, esters, glycols, ethers, ethyleneamines, aliphatic naphthas, and water.
10 . The wire of claim 3 wherein the powdered flux is a non-corrosive aluminum flux.
11 . The wire of claim 10 wherein the non-corrosive aluminum flux is aluminum potassium fluoride.
12 . The wire of claim 10 wherein the non-corrosive aluminum flux contains potassium tetrafluoroaluminate.
13 . The wire of claim 3 wherein the polymer is an acrylic polymer.
14 . The wire of claim 3 wherein:
the polymer is derived from a carbon dioxide; and
the polymer is biocompatible such that thermal decomposition yields a carbonate which vaporizes for substantially complete removal.
15 . The wire of claim 3 wherein the polymer is a poly alkylene carbonate produced by copolymerization of carbon dioxide with at least one epoxide.
16 . A method of manufacturing a wire for brazing or soldering comprising the steps of:
drawing the wire through a flux reservoir, the wire including an area for flux solution to be inserted;
exerting pressure on a flux dispensing cartridge that contains the flux solution;
forcing the flux solution from the dispensing cartridge into the reservoir;
at least partially filling the area for flux solution by passing the wire through the reservoir containing the flux solution;
wiping off an excess of the flux solution as the wire exits the reservoir;
causing the flux solution to solidify within the area for the flux solution on the wire; and
spooling the wire.
17 . The method of claim 16 further comprising the steps of:
after causing the flux solution to solidify, cutting the wire to a predetermined length; and
forming an annular ring of the wire.
18 . A wire for use in a brazing or soldering operation, the wire comprising:
an elongated body of a metallic material;
a channel formed along a length of the elongated body having an opening; and
a flux solution within the channel comprising a flux material and binder material.
19 . The wire of claim 18 wherein the binder is a polymer-base material.
20 . The wire of claim 19 wherein the polymer-base material comprises a polymer selected from a group consisting of an acrylic polymer and a polymer produced from copolymerization of carbon dioxide.
21 . The wire of claim 20 wherein the polymer is a poly alkylene carbonate.
22 . The wire of claim 18 wherein the flux material is aluminum-based.
23 . The wire of claim 18 wherein the flux material is cesium-based.
24 . The wire of claim 18 wherein the metallic material of the elongated body is an aluminum alloy.