Brazing Material Containing A Flux

Abstract

A wire for use in a brazing or soldering operation is provided. The wire preferably includes a body formed of a metallic material. A flux solution is provided within a channel along at least a portion of the length of the body and a surface of the flux solution is exposed. The body is preferably formed into an annular ring having an inner wall and an opposing outer wall. The flux solution preferably includes a solvent, a polymer dissolved in the solvent, and a powdered flux added to the polymer solution.

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; and   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 1  wherein the flux solution further comprises:
 a solvent, 
 a polymer wherein the polymer is one of a granulated or a beaded polymer and is dissolved in the solvent, and 
 a powdered flux added to the polymer solution. 
 
     
     
         4 . The wire of  claim 1  wherein the metallic material is selected from a group consisting of nickel, cobalt, copper, gold, aluminum, magnesium, silver, a combination of these metals, and an alloy formed from these metals. 
     
     
         5 . The wire of  claim 2  wherein the metallic material in the ring is silver. 
     
     
         6 . The wire of  claim 2  wherein the metallic material in the ring is aluminum. 
     
     
         7 . The wire of  claim 2  wherein the metallic material in the ring is an alloy made of zinc and aluminum. 
     
     
         8 . The wire of  claim 4  wherein the metallic material is a zinc and aluminum alloy. 
     
     
         9 . The wire of  claim 3  wherein the solvent is selcected from a group consisting of glycol ether acetates, alcohols, polyols, alkanolamines, aromatic solvents, terpenes, ketones, n-methyl-2-pyrroloidone, esters, glycols, ethers, ethyleneamines, aliphatic naphthas, and water. 
     
     
         10 . The wire of  claim 3  wherein the powdered flux is a non-corrosive aluminum flux. 
     
     
         11 . The wire of  claim 10  wherein the non-corrosive aluminum flux is aluminum potassium fluoride. 
     
     
         12 . The wire of  claim 10  wherein the non-corrosive aluminum flux contains potassium tetrafluoroaluminate. 
     
     
         13 . The wire of  claim 3  wherein the polymer is an acrylic polymer. 
     
     
         14 . The wire of  claim 3  wherein:
 the polymer is derived from a carbon dioxide; and 
 the polymer is biocompatible such that thermal decomposition yields a carbonate which vaporizes for substantially complete removal. 
 
     
     
         15 . The wire of  claim 3  wherein the polymer is a poly alkylene carbonate produced by copolymerization of carbon dioxide with at least one epoxide. 
     
     
         16 . A method of manufacturing a wire for brazing or soldering comprising the steps of:
 drawing the wire through a flux reservoir, the wire including an area for flux solution to be inserted;   exerting pressure on a flux dispensing cartridge that contains the flux solution;   forcing the flux solution from the dispensing cartridge into the reservoir;   at least partially filling the area for flux solution by passing the wire through the reservoir containing the flux solution;   wiping off an excess of the flux solution as the wire exits the reservoir;   causing the flux solution to solidify within the area for the flux solution on the wire; and   spooling the wire.   
     
     
         17 . The method of  claim 16  further comprising the steps of:
 after causing the flux solution to solidify, cutting the wire to a predetermined length; and 
 forming an annular ring of the wire. 
 
     
     
         18 . 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.   
     
     
         19 . The wire of  claim 18  wherein the binder is a polymer-base material. 
     
     
         20 . The wire of  claim 19  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. 
     
     
         21 . The wire of  claim 20  wherein the polymer is a poly alkylene carbonate. 
     
     
         22 . The wire of  claim 18  wherein the flux material is aluminum-based. 
     
     
         23 . The wire of  claim 18  wherein the flux material is cesium-based. 
     
     
         24 . The wire of  claim 18  wherein the metallic material of the elongated body is an aluminum alloy.