Filler metal with flux for brazing and soldering and method of using same

Abstract

A brazing or soldering wire has a pair channels recessed therein. A divider separates the pair of channels. The divider has opposing walls extending outwardly from corresponding base portions of the pair of channels. A first engagement surface is located between the opposing walls. A pair of outer walls is separated by the pair of channels and the divider. A second engagement surface is formed between an outer surface of the elongated wire and a terminal end of one of the outer walls and is substantially coplanar with the first engagement surface. A third engagement surface is formed between the outer surface of the elongated wire and a terminal end of the other of the outer walls and is substantially coplanar with the first engagement surface. A cured flux solution is located within the pair of channels.

1 - 20 . (canceled) 
     
     
         21 . A wire for use in a brazing or soldering operation, the wire comprising:
 an elongated body of a metallic material having a base wall having an inner surface and an outer surface, a first angled wall extending from a first side of the base wall and a second angled wall extending from a second side of the base wall, the first angled wall extending at a first obtuse angle with respect to the base wall and the second angled wall extending at a second obtuse angle with respect to the base wall, wherein the first angle wall, base wall and the second angled wall form a channel; and,   a flux solution in the channel.   
     
     
         22 . The wire of  claim 21  wherein the first angled wall includes an inner angled wall and an outer angled wall parallel to the inner angled wall. 
     
     
         23 . The wire of  claim 22  wherein the second angled wall includes an inner angled wall and an outer angled wall parallel to the inner angled wall of the second angled wall. 
     
     
         24 . The wire of  claim 23  wherein the first angled wall includes a first end having an engagement surface between the inner angled wall and the outer angled wall of the first angled wall. 
     
     
         25 . The wire of  claim 24  wherein the second angled wall includes a first end having an engagement surface between the inner angled wall and the outer angled wall of the second angled wall. 
     
     
         26 . The wire of  claim 25  wherein the engagement surface of the first angled wall and the engagement surface of the second angled wall are parallel to the inner surface of the base wall. 
     
     
         27 . The wire of  claim 25  wherein the engagement surface of the first angled wall and the engagement surface of the second angled wall are coplanar. 
     
     
         28 . The wire of  claim 21  wherein the flux is a cured flux solution. 
     
     
         29 . The wire of  claim 28  wherein the cured flux solution comprises a polymer-based binder material and a flux material. 
     
     
         30 . The wire of  claim 21  wherein the elongate metal is in a ring shape. 
     
     
         31 . The wire of  claim 30  wherein the channel forms an inner circumference of the ring shape. 
     
     
         32 . The wire of  claim 21  wherein the elongated metal has a trapezoidal cross-sectional shape. 
     
     
         33 . The wire of  claim 21  wherein the first obtuse angle is greater than 180 degrees and less than 260 degrees. 
     
     
         34 . The wire of  claim 33  wherein the first obtuse angle is greater than 200 degrees and less than 250 degrees. 
     
     
         35 . The wire of  claim 21  wherein the first obtuse angle is equal to the second obtuse angle. 
     
     
         36 . The wire of  claim 27  wherein the flux has an outer surface that is coplanar with the first engagement surface and the second engagement surface. 
     
     
         37 . The wire of  claim 25  wherein the engagement surface of the first angled wall has a first width, the engagement surface of the second angled wall has a second width and the channel has a third width wherein the third width is greater than the sum of the first width and the second width. 
     
     
         38 . The wire of  claim 23  wherein the base wall has a first thickness between the inner wall and the outer wall of the base wall, the first angled wall has a second thickness between the inner angled wall and the outer angled wall of the first angled wall, and the second angled wall has a third thickness between the inner angled wall and the outer angled wall wherein the first thickness, second thickness and third thickness are equal. 
     
     
         39 . The wire of  claim 21  wherein the channel has a width between a distal end of the first angled wall and a distal end of the second angled wall greater than a width of the outer wall of the base wall. 
     
     
         40 . The wire  claim 23  wherein the inner angled wall and outer angled wall of the first angled wall are parallel, and the inner angled wall and outer angled wall of the second angled wall are parallel.