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 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 1 ) in the channel ( 14 ).

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;   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 2  wherein the channel forms a portion of the inner wall. 
     
     
         4 . The wire of  claim 3  wherein the flux solution within the channel forms a portion of the inner wall. 
     
     
         5 . The wire of  claim 4  wherein a top surface of the flux solution within the channel is located below an imaginary plane spanning across uppermost points forming the channel. 
     
     
         6 . The wire of  claim 5  wherein the imaginary plane is located entirely along the inner wall of the ring. 
     
     
         7 . The wire of  claim 1  wherein a width of the channel is 30% to 70% of a major axis of the wire. 
     
     
         8 . A method of preparing a wire for use in a brazing or soldering operation comprising 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 in the elongated wire with an opening on an outer surface of the wire;   depositing a flux solution through the opening into the channel such that a portion of the flux solution is exposed in the opening; and   curing the flux solution within the channel.   
     
     
         9 . The method of  claim 8  wherein the step of depositing the flux solution comprises the steps of:
 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 at or adjacent the outlet having a passageway therethrough wherein the shape of the passageway regulates the amount and location of the flux solution left on the elongated wire. 
 
     
     
         10 . The method of  claim 8  further comprising the steps of:
 after the curing step, cutting the elongated wire to a predetermined length; and 
 forming an annular ring of the elongated wire. 
 
     
     
         11 . The method of  claim 10  wherein the forming of the annular ring step comprises the step of:
 creating an outer wall and an inner wall with the channel containing the flux solution. 
 
     
     
         12 . The method of  claim 8  wherein the curing step includes the step of:
 providing a source of power; and 
 electrically connecting the elongated wire to the source of power. 
 
     
     
         13 . 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.   
     
     
         14 . The wire of  claim 13  wherein the binder material is a polymer-base material. 
     
     
         15 . The wire of  claim 14  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. 
     
     
         16 . The wire of  claim 15  wherein the polymer is a poly alkylene carbonate. 
     
     
         17 . The wire of  claim 13  wherein the flux material is aluminum-based. 
     
     
         18 . The wire of  claim 13  wherein the flux material is cesium-based. 
     
     
         19 . The wire of  claim 13  wherein the metallic material of the elongated body is an aluminum alloy. 
     
     
         20 . The wire of  claim 13  wherein the metallic material is a zinc/aluminum alloy comprising at least 2 percent by weight aluminum.