U.S. patent application number 16/125967 was filed with the patent office on 2019-02-28 for filler metal with flux for brazing and soldering and method of making and using same.
The applicant listed for this patent is Bellman-Melcor Development, LLC. Invention is credited to Steven Campbell, John Scott.
Application Number | 20190061067 16/125967 |
Document ID | / |
Family ID | 40252123 |
Filed Date | 2019-02-28 |
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United States Patent
Application |
20190061067 |
Kind Code |
A1 |
Campbell; Steven ; et
al. |
February 28, 2019 |
FILLER METAL WITH FLUX FOR BRAZING AND SOLDERING AND METHOD OF
MAKING AND USING SAME
Abstract
A wire (10) for use in a brazing or soldering operation has an
elongated body (12) of a metallic material. The elongated body (12)
has an outer surface (18). A channel (14) is formed along a length
of the body. The channel (14) has an opening (A.sub.1). A flux
solution (22) is deposited within the channel (14) and along the
length of the body. The flux solution (22) covers a portion of the
outer surface (18). A portion of the flux solution (22) is exposed
through the opening (A.sub.1) in the channel (14).
Inventors: |
Campbell; Steven; (Mokena,
IL) ; Scott; John; (New Lenox, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bellman-Melcor Development, LLC |
Tinley Park |
IL |
US |
|
|
Family ID: |
40252123 |
Appl. No.: |
16/125967 |
Filed: |
September 10, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14816164 |
Aug 3, 2015 |
10071445 |
|
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16125967 |
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13625206 |
Sep 24, 2012 |
9095937 |
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14816164 |
|
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12176126 |
Jul 18, 2008 |
8274014 |
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13625206 |
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11753045 |
May 24, 2007 |
7858204 |
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12176126 |
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60808416 |
May 25, 2006 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/2902 20150115;
C22F 1/165 20130101; B23K 35/40 20130101; B23K 35/0227 20130101;
B23K 35/406 20130101 |
International
Class: |
B23K 35/02 20060101
B23K035/02; C22F 1/16 20060101 C22F001/16; B23K 35/40 20060101
B23K035/40 |
Claims
1-20. (canceled)
21. A wire for brazing and soldering comprising: an elongated body
of a brazing material, the elongated body having a central axis; a
plurality of channels formed along the elongated body, each channel
having an opening that is transverse to the central axis of the
elongated body, each channel is only partially filled with a flux
solution to a height below an imaginary plane spanning across the
channel opening, wherein the imaginary plane is aligned with
uppermost points forming the opening.
22. The wire of claim 21 formed into an annular ring.
23. The wire of claim 22 wherein each of the channel openings is
along an inner circumference of the annular ring.
24. The wire of claim 22 wherein a first portion of the channel
openings of the plurality of channels is along an inner
circumference of the annular ring and a second portion of the
channel openings of the plurality of channels is along an outer
circumference of the annular ring.
25. The wire of claim 21 wherein the flux solution comprises a flux
material and binder material.
26. The wire of claim 25 wherein the binder material is a
polymer-base material.
27. The wire of claim 26 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.
28. The wire of claim 26 wherein the polymer is a poly alkylene
carbonate.
29. The wire of claim 26 wherein the flux material is
aluminum-based.
30. The wire of claim 26 wherein the flux material is
cesium-based.
31. The wire of claim 21 wherein the brazing material of the
elongated body is an aluminum alloy.
32. The wire of claim 21 wherein the brazing material of the
elongated body is a zinc/aluminum alloy comprising at least having
at least 2 percent by weight aluminum.
34. The wire of claim 21 wherein a surface of the flux solution in
each channel is exposed through the opening in each channel.
35. The wire of claim 22 wherein the ring includes ten
channels.
36. The wire of claim 21 wherein the flux solution includes a
surface having an outwardly concave shape.
37. The wire of claim 21 wherein the elongated body has a generally
circular cross-sectional shape between each of the plurality of
channels.
38. A wire for brazing and soldering comprising: an elongated body
of a brazing material, the elongated body having a central axis; a
plurality of channels formed along the elongated body, each channel
having an opening that is transverse to the central axis of the
elongated body, each channel is only partially filled with a flux
solution to a height below an imaginary plane spanning across the
channel opening, wherein the imaginary plane is aligned with
uppermost points forming the opening, and wherein each channel of
the plurality of channels is spaced from an adjacent channel by a
separating portion of the elongated body and wherein each channel
extends about 10% to 50% of a height of a separating portion.
39. The wire of claim 38 formed into an annular ring wherein each
of the channel openings is along an inner circumference of the
annular ring.
40. The wire of claim 38 formed into an annular ring wherein a
first portion of the channel openings of the plurality of channels
is along an inner circumference of the annular ring and a second
portion of the channel openings of the plurality of channels is
along an outer circumference of the annular ring.
Description
RELATED APPLICATION
[0001] This Application is a continuation of U.S. patent
application Ser. No. 14/816,164 filed on Aug. 3, 2015, which is a
continuation of U.S. patent application Ser. No. 13/625,206 filed
Sep. 24, 2012, now U.S. Pat. No. 9,095,937, which is a continuation
of U.S. patent application Ser. No. 12/176,126 filed Jul. 18, 2008,
now U.S. Pat. No. 8,274,014, which is a continuation-in-part of
U.S. patent application Ser. No. 11/753,045 filed on May 24, 2007,
now U.S. Pat. No. 7,858,204, which claims the benefit of
Provisional Patent Application No. 60/808,416 filed on May 25,
2006.
TECHNICAL FIELD
[0002] The invention relates to relates to wire used in brazing and
soldering. More particularly, the present invention is directed to
a channeled wire having a flux solution deposited therein for use
in joining two similar or dissimilar metals in industrial
applications.
BACKGROUND OF THE INVENTION
[0003] Brazing and soldering are two methods commonly used to join
two similar or dissimilar metals together. These processes
typically involve joining metal components together by disposing a
brazing composition such as an aluminum or metal alloy adjacent to
or between the faying surfaces, i.e., the surfaces to be joined.
The brazing filler alloy and the faying surfaces are then heated to
the brazing temperature, typically above the melting temperature of
the braze alloy but below the melting temperature of the components
to be joined. The brazing composition then melts, flows into the
joint by capillary action and forms a fillet and seal that bonds
the faying surfaces.
[0004] In most cases, these processes require a chemical flux in
addition to the filler alloy. The flux prepares the base metals to
accept the filler alloy which results in a strong bond. Fluxes are
generally grouped under two categories: corrosive (must be removed)
and non-corrosive (residues are left on the part).
[0005] Historically, the alloy and flux are applied as two separate
steps. In recent years however, an increasing number of options
have been developed that combine the filler alloys and fluxes in
one complete form. These developments have taken place with brazing
alloys that are aluminum based and silver based.
[0006] For instance, Omni Technologies Corporation (Epping, N.H.)
developed a flux core wire, which is sold under the trademark
SIL-CORE.TM.. In order to accomplish this, Omni takes aluminum in
the form of narrow sheet, deposits a quantity of powdered flux down
the middle, and then form rolls the narrow sheet around the flux.
This material is then put through draw dies to reduce the diameter
and compact the flux inside. From this process, Omni offers several
wire diameters as well as different flux compositions. In addition,
the amount of flux can be changed as needed. This material is
available on spools, large coils and custom fabricated shapes. The
inventors of the present invention believe Omni uses a flux sold by
Solvay Chemical Company under the name NOCOLOK.RTM.. NOCOLOK.RTM.
brand is one of the most widely recognized non-corrosive aluminum
fluxes. This product is described in U.S. Pat. No. 5,781,846, which
is hereby incorporated by reference as if fully set forth herein.
Omni claims the SIL-CORE.TM. product does not contain a binding
agent.
[0007] The S.A. Day Corporation (Buffalo, N.Y.) produces an
aluminum flux coated rod sold under name DAYROD. This rod includes
an aluminum wire cut to 12 inch rods, and dipped in an aluminum
flux bath. After dipping, the rods are hung to dry. Day does not
use NOCOLOK.RTM. brand flux. Instead, Day uses a similar
formulation which is mixed with a polymer-based binder system. This
binder allows for the flux to remain ductile and not brittle. The
flux coated rods can be bent or twisted and the flux will not fall
off.
[0008] Day also produces a flux coated ring. Day purchases metallic
rings from Bellman-Melcor, Inc. The rings are then loaded on a
machine that "paints" a thin coating of flux on the outside edge of
each ring. While the end product is acceptable, it is very slow to
produce and consequently very expensive. Similar to the rods, the
rings can be handled roughly and the flux remains intact.
[0009] Protechno-Richard (France) offers a product very similar to
the Omni product.
[0010] Kin-Met (Korea) produces an extruded product. A powdered
form of aluminum braze alloy is mixed with powdered flux. The
combination is pressurized and extruded into final form.
[0011] Wolverine and Omni teamed up to create a flux coating for
silver based materials. Made from a ductile binder system, this
technology is sold under the name SILVACOTE.TM.. SILVACOTE.TM. is a
continuously coated, flux-coated brazing material.
[0012] The present invention is provided to solve the problems
discussed above and other problems, and to provide advantages and
aspects not provided by prior brazing wires of this type. A full
discussion of the features and advantages of the present invention
is deferred to the detailed description, which proceeds with
reference to the accompanying drawings.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a wire for use in a
brazing or soldering operation. The wire comprises an elongated
body, a channel, and a flux solution. The elongated body is
produced from a metallic material. The body has an outer surface.
The channel is formed along at least a portion of the body. The
channel has an opening. The flux solution is deposited within the
channel and along the length of the body with a surface of the flux
solution being exposed through the opening in the channel.
[0014] The metallic material may be an aluminum alloy, a silver
alloy, a copper alloy, and/or a zinc alloy.
[0015] The elongated body may have a substantially elliptical
cross-sectional shape, a substantially rectangular shape
cross-sectional shape, and or a substantially kidney-shaped
cross-sectional shape.
[0016] The channel may have a substantially rectangular shape.
[0017] The flux solution may be a non-corrosive or corrosive flux
solution.
[0018] The flux solution may include a polymer-base binder.
[0019] The opening may be about 0.030 inches.
[0020] The opening may be about 30% to 70% of a major axis of the
wire.
[0021] The channel may be about 0.020 inches deep.
[0022] The channel may have a depth of about 10% to 50% of a major
axis of the wire.
[0023] The elongated body may be formed into an annular ring having
an inner wall and an opposing outer wall. The channel may form a
portion of the inner wall. The flux solution within the channel may
form a portion of the inner wall, and a top surface of the flux
solution within the channel may be located below a straight line or
imaginary plane spanning across the opening of the channel. The
straight line may be located entirely along the inner wall of the
ring.
[0024] The present invention is also directed to a wire for use in
a brazing or soldering operation. The wire comprises an elongated
body, a channel, and a flux solution. The elongated body is of a
metallic material. The body has a length substantially greater than
a width. The elongated body also has an outer surface. The channel
is formed along a portion of the length of the body and has an
opening. The flux solution is deposited within the channel and
along the portion of the length of the body. The flux solution
covers a portion of the outer surface. A portion of the flux
solution is exposed through the opening in the channel.
[0025] The invention is further directed to a method of preparing a
wire for use in a brazing or soldering operation. The method
comprises the steps of providing an elongated wire, forming a
channel along at least a portion of the length of the elongated
wire, and depositing a flux solution into the channel. The
elongated wire has a length substantially greater than a
cross-sectional width and an outer exposed surface. The channel has
an opening. The flux solution is deposited into the channel such
that a portion of the flux solution is exposed in the opening.
[0026] The channel may span substantially the entire length of the
elongated wire.
[0027] The opening may span substantially the length of the
elongated wire.
[0028] The flux solution may comprise a metallic component and a
polymeric-based component.
[0029] The polymeric-based component may be an acrylic polymer.
[0030] The metallic material may be an aluminum-based powder.
[0031] The invention is also directed to a further method of
preparing a wire for use in a brazing or soldering operation. This
method comprises the steps of: providing an elongated wire having a
length substantially greater than a cross-sectional width and an
outer exposed surface; forming a channel along at least a portion
of the length of the elongated wire, the channel having an opening;
depositing a flux solution through the opening into the channel
wherein a portion of the outer surface of the elongated wire is
covered by the flux solution and a portion of the flux solution is
exposed in the opening; and curing the flux solution within the
channel.
[0032] The method may comprise the further steps of: cutting the
elongated wire to a predetermined length after the curing step; and
forming an annular ring of the elongated wire. The forming the
annular ring step may comprise the sub-step of creating an inner
wall and an opposing outer wall, the inner wall including the
channel containing the flux solution.
[0033] The depositing the flux solution step may also comprise the
following sub-steps: providing a chamber including a volume of the
flux solution; passing the elongated wire through an inlet in the
chamber; removing the elongated wire from the chamber through an
outlet in the chamber; and passing the wire through a die located
adjacent the outlet; the die having a passageway therethrough
wherein the shape of the passageway regulates the amount and
location of the flux solution left on the elongated wire.
[0034] The curing step may include the step of: providing a source
of power; and electrically connecting the elongated wire to the
source of power.
[0035] Another aspect of the present invention is directed to a
wire for use in a brazing or soldering operation. The wire
comprises an elongated body of a metallic material, a channel
formed along a length of the elongated body, the channel having an
opening, and a flux solution within the channel, the flux solution
comprising a flux material and binder material.
[0036] The binder material may be a polymer-base material. The
polymer-base material may comprise a polymer selected from a group
consisting of an acrylic polymer and a polymer produced from
copolymerization of carbon dioxide. The polymer may be a poly
alkylene carbonate.
[0037] The flux material may be aluminum-based or cesium-based.
[0038] The metallic material of the elongated body may be an
aluminum alloy, or the metallic material may be a zinc/aluminum
alloy comprising at least having at least 2 percent by weight
aluminum.
[0039] Another aspect of the invention is directed to a wire for
use in a brazing or soldering operation. The wire comprises an
elongated body, a first channel, a second channel, a first volume
of a first flux solution, and a second volume of a second flux
solution. The elongated body is produced from a metallic material.
The first channel has a first opening formed along a length of the
elongated body. The second channel has a second opening formed
along a length of the elongated body. The first volume of a first
flux solution is located within the first channel and along at
least a portion of the length of the elongated body. The second
volume of a second flux solution is located within the second
channel and along at least a portion of the length of the elongated
body.
[0040] This aspect of the invention may include several other
design chracteristics, alone or in any combination. For instance,
the first volume of the first flux solution and the second volume
of the second flux solution of the wire of this aspect of the
invention may not be equal. Also, the top surface of the first
volume of the first flux solution may be located below an imaginary
plane spanning across uppermost points forming the first opening in
the first channel. Each channel may comprise a pair of sidewalls
separated by a base, each sidewall extending radially outwardly
from the base and forming an angle with the base greater than 90
degrees. The first flux solution and the second flux solution may
have different chemistries. The openings in the first and second
channels may be parallel or transverse to a central axis of the
wire. The wire may form a ring and the first channel is located
along a radially inner wall and the second channel is located along
a radially outer wall. The first and second flux solutions may
comprise a flux material and binder material. The metallic material
of the elongated body may be an aluminum alloy. A surface of the
first flux solution may be exposed through the opening in the first
channel. A surface of the second flux solution may be exposed
through the opening in the second channel. The opening in the first
channel may be 30% to 70% of the length of a major axis of the
wire. The second channel may be 30% to 70% of the length of a major
axis of the wire. The first and second channels may be transverse
to a central axis of the wire.
[0041] Other features and advantages of the invention will be
apparent from the following specification taken in conjunction with
the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] To understand the present invention, it will now be
described by way of example, with reference to the accompanying
drawings in which:
[0043] FIG. 1 is a cross-sectional view taken transverse to the
length of a first braze wire of the present invention;
[0044] FIG. 2 is a cross-sectional view taken transverse to the
length of a second braze wire of the present invention;
[0045] FIG. 3 is a cross-sectional view taken transverse to the
length of a third braze wire of the present invention;
[0046] FIG. 4 is a cross-sectional view taken transverse to the
length of a fourth braze wire of the present invention;
[0047] FIG. 5 is a perspective view of a lengthwise section of a
typical braze wire of the present invention;
[0048] FIG. 6 is a perspective view of a wire of the present
invention formed into an annular ring;
[0049] FIG. 7 is a cross-sectional view of the annular ring of FIG.
6;
[0050] FIG. 8 is a perspective view of a lengthwise section of a
typical braze wire of the present invention;
[0051] FIG. 9 is a top view of the braze wire of FIG. 8 formed in
the form of an annular ring;
[0052] FIG. 10 is a schematic view of a manufacturing method of
forming a wire of the present invention;
[0053] FIG. 11 is a partial cross-sectional view of a pair of work
rolls for rolling a channel into an elongated wire;
[0054] FIG. 12 is a perspective view of a flux solution chamber and
a die/wiper for removing excess flux solution on a wire pf the
present invention;
[0055] FIG. 13 is a cross-sectional view of a method for joining a
pair of tubular members using a wire of the present invention
formed as an annular ring; and
[0056] FIG. 14 is a cross-sectional view of an alternative
embodiment of the braze wire of the present invention.
DETAILED DESCRIPTION
[0057] While this invention is susceptible of embodiments in many
different forms, there is shown in the drawings and will herein be
described in detail preferred embodiments of the invention with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the broad aspect of the invention to the
embodiments illustrated.
[0058] The present invention is directed to a brazing/soldering
wire for use in multiple metal combinations including aluminum
applications. The end use for these materials is typically
industrial applications, such as automobiles and automobile
component manufacturing as well as other heat transfer applications
including air conditioning and refrigeration manufacture. Of
course, other applications can be had as well. The
brazing/soldering wire of the present invention may be used on many
different materials including aluminum alloys, zinc alloys, copper
alloys and silver alloys, etc. The wire itself can be produced from
an aluminum alloy, a silver alloy, a copper alloy, and/or a zinc
alloy.
[0059] The Wire
[0060] The present invention includes a solid wire 10 rather than a
narrow sheet or strip that is preferably very robust and will not
move when assembled onto component parts. This is important because
in air conditioning applications, braze wire is commonly supplied
in ring-form. The rings are friction fit or snuggly placed around
tubes. Because current ring shaped braze wires often lose their
grip on component parts, causing the rings to shift or fall off
altogether, rings formed from the wire 10 of the present invention
are specifically constructed so as to be less likely to plastically
deform by the friction fit about the component parts. As a result,
they are less likely to shift or fall off prior to the brazing or
soldering process. This important aspect of the present invention
is described in more detail below.
[0061] Referring to FIGS. 1 though 5, a wire 10 having an elongated
body 12 with a channel 14 reformed along a length of an outer
surface 18 is illustrated. The wire 10 is formed from a metallic
material supplied at a diameter of about 0.031 inches to 0.125
inches (0.787 mm to 3.18 mm), preferably 0.079 inches to 0.090
inches (2.00 mm to 2.29 mm), or any range or combination of ranges
therein. The wire 10 has been rolled or reformed to a new geometric
shape, such as substantially rectangular or elliptical
configuration having a major axis D.sub.1 of about 0.105 inches
(2.67 mm) and a minor axis C.sub.1 of about 0.048 inches (1.22 mm).
The overall shape of the reformed wire 10 may also be described as
kidney-shaped, U-shaped, or C-shaped in cross-section. A
discontinuity 20 in the outer surface 18 and, thus the shape of the
wire 10, is caused by the channel 14 formed therein. It would be
appreciated by one of ordinary skill in the art that dimensions of
the wire 10 may vary greatly based on customer requirements.
[0062] The channel 14 typically has a substantially rectangular or
conic section shape having an opening A.sub.1 parallel to a central
axis 19 of the wire 10 of about 0.030 inches (0.76 mm) and a depth
B.sub.1 of about 0.020 inches (0.51 mm). Preferably, the opening
A.sub.1 is about 30% to 70% of the starting diameter of the wire or
a major axis of the reformed wire, and the channel 14 has a depth
B.sub.1, about 10% to 50% of the starting diameter of the wire or a
major axis of the reformed wire. Again, it would be appreciated by
one of ordinary skill in the art that dimensions of the channel 14
may vary greatly based on customer requirements.
[0063] The channel 14 is at least partially filled with a volume of
flux solution 22. The volume of flux solution 22 per length of the
wire 10 is determined by the end use for the wire. However, it is
preferable for the entire volume of flux solution 22 to be
positioned within the channel 14 and for the flux solution to be
exposed through the opening in the channel 14. Thus, the remaining
portions of the outer surface 18 of the wire are free of flux
solution 22. A top surface of the flux solution 22 is preferably
located below an imaginary line or plane 24 spanning the uppermost
surface of the opening A.sub.1 of the channel 14. (See FIG. 3).
[0064] The flux solution 22 preferably comprises a polymer-based
binder combined with a flux material. Because the flux solution 22
includes a polymer-based binder, the wire 10 may be manipulated
into virtually any shape without disturbing the flux solution 22.
Thus, the wire 10 of the present invention may be provided on
spools, coils, straight rods and most importantly made to order
custom performs, such as rings and the like. The wire 10 may
further be supplied in unlimited wire sizes with different flux
formulations as well as different alloy/flux ratios.
[0065] Referring to FIGS. 6-7, a wire 10 of the present invention
has been formed into a pre-form. The pre-form may be a rod, slug,
or any other custom shape. In the embodiment illustrated the
pre-form is an annular ring 30. The ring 30 is formed such that the
channel 14 bearing the flux solution 22 forms an inner wall 32 of
the ring 30. An outer wall 34 of the ring 30 is free of flux
solution 22. By locating the flux/polymer solution 22 on the inner
wall of the ring 30, two advantages are realized. First, the flux,
within the flux solution 22, is located adjacent one of the parts
to be joined. Second, the flux solution 22 is in compression,
rather than tension, wherein the solution 22 tends to remain within
the channel 14 rather than flaking, pealing, or otherwise falling
off of the wire 10.
[0066] Further to the structure of the inner wall of the ring 30,
the imaginary straight line or plane 24, of which the top surface
of the flux solution 22 is preferably below, is located entirely
along the inner wall 32 of the ring 30. Thus, the opening A.sub.1
of the channel 14 is also located entirely along the inner wall 32
of the ring 30. In other words, the flux solution 22 forms a
portion of the inner wall 32. More particularly, the top surface of
the flux solution 22 forms at least a portion of the inner wall
32.
[0067] Referring to FIG. 8, an alternative embodiment of a wire 10
of the present invention is illustrated. In this embodiment, a
plurality of channels 14 are formed in the wire 10. The channels 14
are formed along a transverse length of the elongated body 12, such
that openings are transverse to the central axis 19 of the wire 10.
In other words, the length of the wire 10 forming the channel 14 is
transverse to the elongated body 12 of the wire 10. Each channel 14
is otherwise as described above, each channel 14 being at least
partially filled with a flux solution 22, preferably filled to a
height below the imaginary line or plane 24. The shapes and
dimensions of the wire 10 are, likewise, as described above.
[0068] FIG. 9 is an illustration of the wire 20 of FIG. 8 reformed
to an annular ring 30. The ring 30 is formed such that the channel
14 bearing the flux solution 22 forms an inner wall 32 of the ring
30. In this example, the outer wall 34 of the ring 30 includes a
section or portion of each channel 14 and thus the flux solution 22
within each channel 22 also forms a portion of the outer wall 34 of
the ring 30. This configuration achieves the advantages of the
previous embodiment as well as the additional benefit that upon
melting or liquefying, the flux in the flux solution 22 is free to
flow from each channel 14 in a direction transverse to the length
of the elongated body 12. It would be appreciated by one of
ordinary skill in the art that the channels 14 may be completely
contained along the inner wall 32 of the ring, similar to the
single channel 14 of the FIGS. 6-7, or that some percentage of the
channels 14 may be completely contained along the inner wall 32 of
the ring 34 with some percentage of the channels 14 forming a
portion of both the inner and outer walls 32,34 of the ring. It
would be still further appreciated by one of ordinary skill that
some percentage of the channels 14 may be completely contained on
the inner wall 32, that some percentage of the channels 14 may be
completely contained on the outer wall 34, and that some percentage
of the channels 14 may form a portions of the inner and outer wall
32,34 of the ring 30. In other words, the channels 14 may be
distributed about the circumference of the outer surface 18 of the
elongated body 12.
[0069] Now referring specifically to FIG. 14, another alternative
embodiment of the wire 10 of the present invention is illustrated.
The dimensions of the wire 10 of this embodiment are the same or
similar to the dimensions previously discussed. This wire 10
includes a plurality of channels, preferably two. Accordingly, the
wire has an elongated body 12 which includes at least two channels
14a,14b located lengthwise along the outer surface 18 of the wire
10. These channels 14a,14b are separated by a portion of the outer
surface 18 and are preferably located on opposing sides of the wire
10. Thus, the channels 14a,14b may be spaced 180 degrees apart and
may spiral about the outer surface 18.
[0070] Each channel 14a,14b forms a separate discontinuity 20a, 20b
in the outer surface 18 and has a base 40 joining a pair of
opposing sidewalls 44a,44b. The discontinuities 20a,20b alter the
outer surface 18 and, thus the shape of the wire 10. It would be
appreciated by one of ordinary skill in the art that dimensions of
the wire 10 may vary greatly based on customer requirements.
Furthermore, the channels 14a,14b may have disparate volumes or may
have equal volumes depending on end use requirements, and/or the
volume of flux required. In other words, the ratio of the flux to
the wire volume may be varied from channel to channel. Moreover,
the chemistry of the flux in one channel may be varied
comparatively to the chemistry of the flux in a second channel.
[0071] The base 40 is generally planar as illustrated but may be
curved or bowed, either convexly or concavely or some combination
thereof. The sidewalls 44a,44b angle radially outwardly from the
base 40 such that the sidewalls 44a,44b form angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d with the
base 40. The angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d may be less
than, equal to, or greater than 90 degrees. Preferably, the angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d are greater
than 90 degrees; more preferably, the angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d are between
90 and 150 degrees; and most preferably, the angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d are between
90 and 120 degrees; the angles
.alpha..sub.a,.alpha..sub.b,.alpha..sub.c,.alpha..sub.d may be any
range or combination of ranges therein, collectively (all equal) or
individually (disparate values or some combination of equal and
unequal values).
[0072] The channels 14a14b are at least partially filled with
separate volumes of flux solution 22a,22b. The volume of flux
solution 22a,22b per length of the wire 10 is determined by the end
use for the wire 10. However, it is preferable for the entire
volume of flux solution 22a,22b to be positioned within the
channels 14a,14b and for the flux solution to be exposed through
the opening in the channel 14. Thus, the remaining portions of the
outer surface 18 of the wire 10 are free of flux solution 22. A top
surface of the flux solution 22a,22b may be located above, below,
or co-planar with the an imaginary line or plane spanning the
uppermost surface of the opening A.sub.1,A.sub.2 of each channel
14a,14b. Of course, the separate top surfaces of the flux solution
22a,22b in the first and second channels 14a,14b respectively, may
have different heights as shown in FIG. 14.
[0073] There are several advantages of the wires of the present
invention. For example, the raw material is cheaper and the process
speed is significantly faster than any other product combining wire
and flux. As compared to the Omni product, the wires 10 of the
present invention include a flux solution which is exposed along a
length of the wire 10. The flux solution 22 is not encased. As a
result, this allows the flux within the flux solution 22 to melt
and release from the wire prior to the alloy of the wire
melting.
[0074] The Flux Solution
[0075] The flux solution 22 is preferably prepared in the following
manner. A granulated or beaded polymer is first dissolved in a
solvent to form a liquefied suspension. The polymeric material may
be derived from an acrylic polymer, such as a proprietary acrylic
polymer manufactured by S.A. Day Mfg. Co. The polymeric material,
however, is preferably derived from a carbon dioxide rather than a
petroleum; it is enzyme degradable; and it is biocompatible where
thermal decomposition yields a carbonate which vaporizes for
complete removal, leaving minimal ash residue. The products of
combustion are non-toxic (primarily carbon dioxide and water).
Accordingly, the polymer is generally a thermoplastic, preferably a
copolymer, more preferably a poly alkylene carbonate produced
through the copolymerization of CO.sub.2 with one or more
epoxides.
[0076] Once the polymer is dissolved in the solvent, a flux is then
added in powder form. Any suitable flux, corrosive and
non-corrosive, can be used depending on the desired end use. The
resulting solution is a thick, homogeneous mixture having a
paste-like consistency similar to caulk.
[0077] The Method of Manufacture
[0078] As illustrated in FIGS. 10-12, the channel 14 (or channels
14a,14b) is formed by a roll forming operation. A rolling mill 100
having an upper roll 102 and a complementary lower roll 104 imparts
a specific, pre-designed shape to the wire 10. The profile of the
upper and lower rolls 102,104 is determined by the characteristics
desired by the rolled wire, i.e. designed to accommodate a specific
volume of flux required per length of wire or flux/wire metal
ratio. In short, the profiles of the complementary rolls 102,104
form the wire's profile at the bite of the rolls 102,104, and the
rolls 102,104 may be changed for different profiles desired.
[0079] As the wire 10 exits the rolling operation, the flux
solution 22 (or flux solutions 22a,22b) is added to the channel 14.
This is accomplished by inserting the flux solution 22 within a
dispensing cartridge 108. An external source of pressure, shown
schematically at reference number 112, forces the solution 22 from
the cartridge 108 to a holding chamber or die chamber 116 wherein a
bath of the solution 22 is generated within the chamber 116. The
amount of flux solution 22 forced from the cartridge 108 to the
chamber 116 is controlled by a metering device.
[0080] The reformed wire 10 enters the chamber 116 through an
opening at one end of the chamber 116 so that the solution 22 coats
the entire surface of the wire 10. The solution 22 also enters the
channel 14 through the opening A.sub.1 and fills, or partially
fills, the channel 14 on the wire's outer surface 18. The coated
wire 10 then exits the chamber 116 through a rubber wiper or die
120 which includes a shaped opening or passageway 124. Excess
solution 22 is wiped or cleaned as the wire 10 exits the chamber,
leaving only the desired amount of flux solution 22 on the wire 10,
preferably only within the channel 14. In other words, the die
controls the amount of solution left within the channel 14,
distributes the solution 22 evenly within the channel, and ensures
no excess solution 22 remains on the wire 10.
[0081] Once the channel 14 is filled with the desired volume of
solution 22, the solution is dried or cured to form a solid within
the channel 14. Any number of methods may be used, including
ultra-violet, infra-red, heated fluid pressure, etc. In this
embodiment, electrodes 128a,128b are electrically connected to the
coated wire 10 wherein an electric current from a source of power
132 heats the wire 10 to the desired temperature, generally between
100.degree. F. to 250.degree. F. (38.degree. C. to 121.degree. C.),
preferably between 125.degree. F. to 175.degree. F. (52.degree. C.
to 79.degree. C.), most preferably 150.degree. F. (66.degree. C.),
or any range or combination of ranges therein.
[0082] Once the solution is sufficiently dried, the wire 10 is
spooled for delivery or further process.
[0083] Method of Use
[0084] An example of the present invention is illustrated in FIG.
13. A first tubular metallic part 200 is to be joined to a second
tubular metallic part 204. The first tubular part 200 is passed
through a ring 30 formed of the finished wire, such as the annular
ring 30 illustrated in FIGS. 6-7 and 9. The flux-laden channel 14
of the ring 30 is located adjacent an outer surface 202 of the
first tubular part 200. The second tubular part 204 has a radially
outwardly flared flange 208 to aid in guiding an end portion of the
first tubular part 200 into the second tubular part 204. Unlike
rings of the prior art, the flow of the flux from the ring 30 of
the present invention is not restricted and flows freely upon
heating so as to permit joining of the first and second tubular
parts 200,204 once the alloy of ring 30 melts.
[0085] In a second example, the ring 30 described in conjunction
with the previous example is an aluminum soft temper alloy such
4047 aluminum. The first and second tubular parts 200,204 are
produced from aluminum or an aluminum alloy. The flux solution 22
is produced by dissolving QPAC.RTM. polymer beads manufactured by
Empower Materials Inc. in a methyl ethyl ketone (MEK) solvent. The
flux is a non-corrosive aluminum flux such as the aluminum
potassium fluoride NOCOLOK.RTM. having a melting temperature of
about 1049.degree. F. to 1062.degree. F. (565.degree. C. to
572.degree. C.) or flux B sold by S.A. Day Mfg. Co. containing
potassium tetrafluoroaluminate and cesium tetrafluoroaluminate
having a melting temperature of about 1055.degree. F. (560.degree.
C.).
[0086] The MEK solvent is particularly useful. MEK solvent is
highly evaporative so a low heat will cure the solution 22. Thus,
the flux of this example can be liquefied and released from the
flux solution 22 within the desired range of between 100.degree. F.
(38.degree. C.) and 250.degree. F. (121.degree. C.), most
preferably about 150.degree. F. (66.degree. C.), or any range or
combination of ranges therein. These ranges will sufficiently
evaporate the solvent without causing the remaining flux/polymer
mix 22 to become brittle.
[0087] In a third example, the tubular parts 200,204 are of
aluminum or an aluminum alloy having a melting temperature of about
1150.degree. F. to 1200.degree. F. (620.degree. C. to 650.degree.
C.). The wire is produced from a zinc/aluminum alloy having a
melting temperature of about 850.degree. F. to 950.degree. F.
(454.degree. C. to 510.degree. C.), such as an alloy comprising at
least about 2% aluminum, preferably about 65% to 85% zinc and 15%
to 35% aluminum, and most preferably 78% zinc and 22% aluminum and
having a melting temperature of about 900.degree. F. (482.degree.
C.), or any range or combination of ranges therein. The channel 14
is filled with a polymer/flux blend 22 which activates at about
788.degree. F. to 900.degree. F. (420.degree. C. to 482.degree.
C.), preferably a polymer as described above with a cesium-based
flux in the amount of about 56% to 66% cesium, 27% to 32.2%
fluorine, and 8.6% to 11.4% aluminum or about 6.4% silicon, or any
range or combination of ranges therein. Most preferably, the flux
solution 22 includes a cesium-based flux which has an activation
temperature of about 865.degree. F. (463.degree. C.), such as those
produced by Chemetall GmbH of Frankfurt, Germany.
[0088] While the specific embodiments have been illustrated and
described, numerous modifications are possible without
significantly departing from the spirit of the invention, and the
scope of protection is only limited by the scope of the
accompanying Claims.
* * * * *