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 (A1). 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 (A1) in the channel (14).

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.