Method of manufacturing uncommon form solder wires

Abstract

A method of manufacturing uncommon forms of solder wire without grease or lubricant is provided. The uncommon forms of solder wire is manufactured first by getting a winding rod which can be installed on or removed off the winding machine rapidly, then, obtaining solder wire, and winding the solder wire around the winding rod. Subsequently, fixing the shape as needed and cut the wound solder wire with cutting jigs. Finally, making dotted-line punches for flux to flow out easily, if necessary, and further adjusting the shifted incision gap of each solder wire piece accordingly to the needed shape.

1 . A method of manufacturing uncommon forms solder wires without grease or lubricant comprises:
 supplying a winding rod of profile same to the designated geometric shape of uncommon form solder wires, wherein the rod can be installed on or removed from the winding machine rapidly;   providing solder wire and fixing one end of the solder wire on the winding rod;   winding solder wire around the winding rod with a winding machine to make solder wire into a spiral round string around the rod;   fixing the winding rod with solder wire onto a cutting jig;   cutting solder wire wound on the winding rod with a cutter; and   adjusting the incision gap of each cut solder wire piece.   
   
   
       2 . The method as claimed in  claim 1 , wherein the profile of the winding rod is circular, square, triangular, pentagonal, hexagonal, or of other geometric shapes. 
   
   
       3 . The method as claimed in  claim 1 , wherein the winding rod is composed of replaceable inserts and the profile of the winding rod main body is of designated geometric shape such as cross, asteroid, or combination of basic geometric shapes when the inserts are removed from the winding rod. 
   
   
       4 . The method as claimed in  claim 3 , wherein the inserts are removable from the winding rod and the shape of wound solder wire can be adjusted to fit the profile of the main body of the winding rod with hand tools or customized adjustment jigs. 
   
   
       5 . The method as claimed in  claim 1 , wherein the cutting jig is composed of single or multiple protection covers, a base set, and some adjustment inserts or tools; and the hollow inner space and shape of the cutting jig should match up the rod wound with solder wire firmly according to the designated shape of uncommon form solder wire pieces so that the wound solder wire will be well protected from deformation during cutting processes. 
   
   
       6 . The method as claimed in  claim 5 , wherein the adjusting jigs are placed at both ends of the winding rod in the cutting jig; and push both adjustment jigs towards each other to adjust the incision gap of each uncommon form solder wire piece. 
   
   
       7 . The method as claimed in  claim 6 , wherein the adjusting jig includes single or multiple protection covers; the inner height of the protection cover equals to the sum of the rod diameter and two times of the solder wire diameter; and the length of the inner room of the protection cover to hold the rod wound with solder wire includes a space or a function to adjust incision gap of each uncommon form solder wire pieces on the winding rod after cutting process. 
   
   
       8 . The method as claimed in  claim 5 , wherein the cutting jig includes two protection covers which can hold the cut solder wire pieces firmly on the winding rod and can be slid to adjust and close the incision gap of all uncommon form solder wire pieces on the winding rod simultaneously. 
   
   
       9 . The method as claimed in  claim 1 , wherein there is a groove on the cutting jig for the cutter to assure a straight line cut along the groove during cutting and to assure the safety of the operator from being cut. 
   
   
       10 . The method as claimed in  claim 1  further comprises a groove on the cutting jig for a straight cut on the winding rod wound with solder wire; and the cutter can be customized to provide the functions of cut off, dotted-line punches, or similar continuous tiny incisions on the wound solder wire. 
   
   
       11 . The method as claimed in  claim 1 , wherein the solder wire of designated geometric shape is manufactured to be flattened or to be deformed from traditional appearance in order to increased strength, hardness, and rigidity of solder wire. 
   
   
       12 . The method as claimed in  claim 1 , wherein the solder wire is made of metal, metal alloy, or metal compound for soldering processes. 
   
   
       13 . The method as claimed in  claim 12  wherein the solder wire contains flux during manufacturing processes or coated with flux in the subsequent processes. 
   
   
       14 . The method as claimed in  claim 1  further comprises an automatic machine station to substitute manual operations.