Brazed fifth wheel hitch assembly components and method of constructing the same

Abstract

A brazing connection includes a first component comprising a first material and including a first connection portion, a second component comprising a second material and including a second connection portion, a heating element that is electrically conductive and electrically resistant positioned between the first connection portion of the first component and the second connection portion of the second component, where the heating element is configured to transmit heat when conducting an electrical current, and a brazing material configured to melt when receiving heat from the heating element, thereby connecting the first component to the second component.

The invention claimed is: 
     
         1 . A brazing connection, comprising:
 a first component comprising a first material and including a first connection portion;   a second component comprising a second material and including a second connection portion;   a heating element that is electrically conductive and electrically resistant positioned between the first connection portion of the first component and the second connection portion of the second component, where the heating element is configured to transmit heat when conducting an electrical current; and   a brazing material configured to melt when receiving heat from the heating element, thereby connecting the first component to the second component.   
     
     
         2 . The brazing connection of  claim 1 , wherein the heating element contacts the first connection portion of the first component and the second connection portion of the second component, thereby spacing the second connection portion from the first connection portion. 
     
     
         3 . The brazing connection of  claim 2 , wherein the heating element has a thickness of less than or equal to about 0.040 inches. 
     
     
         4 . The brazing connection of  claim 3 , wherein the thickness of the heating element is between about 0.003 inches and about 0.010 inches. 
     
     
         5 . The brazing connection of  claim 4 , wherein the thickness of the heating element is between about 0.005 inches and about 0.007 inches. 
     
     
         6 . The brazing connection of  claim 1 , wherein the first connection portion includes a recess, and wherein the second connection portion is received within the recess. 
     
     
         7 . The brazing connection of  claim 1 , wherein the heating element includes a wire. 
     
     
         8 . The brazing connection of  claim 1 , wherein the heating element includes a continuous length, and wherein the heating element is configured to make multiple passes between the first connection portion and the second connection portion. 
     
     
         9 . The brazing connection of  claim 1 , wherein the brazing material comprises a paste. 
     
     
         10 . The brazing connection of  claim 9 , wherein the paste includes a flux material. 
     
     
         11 . The brazing connection of  claim 1 , wherein the second material is different than the first material. 
     
     
         12 . The brazing connection of  claim 1 , wherein the brazing material and the heating element cooperate to form a mat. 
     
     
         13 . The brazing connection of  claim 12 , wherein the mat is flexible. 
     
     
         14 . The brazing connection of  claim 12 , wherein the mat is includes a flux material. 
     
     
         15 . The brazing connection of  claim 1 , wherein the heating element includes an electrically conductive portion and an insulating portion positioned between the electrically conductive portion and at least one of the first connection portion and the second connection portion. 
     
     
         16 . A method for forming a brazing connection, comprising:
 providing a first component that comprises a first material and includes a first connection portion;   providing a second component that comprises a second material and includes a second connection portion;   providing a heating element that is electrically conductive and electrically resistant, wherein the heating element is configured to transmit heat when conducting an electrical current;   providing a brazing material configured to melt when receiving heat from the heating element;   positioning the brazing material between the first connection portion of the first component and the second connection portion of the second component;   positioning the heating element between the first connection portion of the first component and the second connection portion of the second component;   heating the heating element by conducting an electrical current through the heating element; and   connecting the first component and the second component by melting the brazing material with the heating element such that the heating element remains between the first and second components subsequent to connecting the first and second components.   
     
     
         17 . The method for forming the brazing connection of  claim 16 , wherein the heating element contacts the first connection portion of the first component and the second connection portion of the second component, thereby spacing the second connection portion from the first connection portion. 
     
     
         18 . The method for forming the brazing connection of  claim 16 , wherein the step of providing the heating element includes providing the heating element with a thickness of less than or equal to about 0.040 inches. 
     
     
         19 . The method for forming the brazing connection of  claim 18 , wherein the thickness of the heating element is between about 0.003 inches and about 0.010 inches. 
     
     
         20 . The method for forming the brazing connection of  claim 19 , wherein the thickness of the heating element is between about 0.005 inches and about 0.007 inches 
     
     
         21 . The method for forming the brazing connection of  claim 16 , wherein the step of providing the first component includes providing the first connection portion with a recess, and wherein the second connection portion of the second component is received within the recess. 
     
     
         22 . The method for forming the brazing connection of  claim 16 , wherein the heating element includes a wire. 
     
     
         23 . The method for forming the brazing connection of  claim 16 , wherein the heating element includes a continuous length, and wherein the heating element makes multiple passes between the first connection portion and the second connection portion. 
     
     
         24 . The method for forming the brazing connection of  claim 16 , wherein the brazing material comprises a paste. 
     
     
         25 . The method for forming the brazing connection of  claim 24 , wherein the paste includes a flux material. 
     
     
         26 . The method for forming the brazing connection of  claim 16 , wherein the second material is different than the first material. 
     
     
         27 . The method for forming the brazing connection of  claim 16 , wherein the brazing material and the heating element cooperate to form a mat. 
     
     
         28 . The method for forming the brazing connection of  claim 27 , wherein the mat is flexible. 
     
     
         29 . The method for forming the brazing connection of  claim 27 , wherein the mat is includes a flux material. 
     
     
         30 . The method for forming the brazing connection of  claim 16 , wherein the heating element includes an electrically conductive portion and an insulating portion positioned between the electrically conductive portion and at least one of the first connection portion and the second connection portion.