Flux Coating Braze Preforms Aerosol Application
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Solution Overview
Problem
The existing methods for applying flux to filler metals and preforms are inefficient, leading to excessive waste, inconsistent coatings, and the need for custom machinery, as well as increased production cycle times and cleaning operations.
Innovation Solution
A method involving a tumbling drum with controlled atmosphere and temperature, where parts are sprayed with flux and then tumbled to cure the coating, allowing for uniform and incremental flux application, or using a conveyor system with plasma cleaning, infrared heating, and ultrasonic flux spraying to achieve consistent flux coating on variously shaped parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If filler material is dipped into a flux bath, then flux is applied to the filler material, but excessive flux adheres to the filler material causing waste and requiring extended cleaning operations
Solution Approach 1:
The patent replaces the traditional mechanical dipping process with an aerosol-based flux application system. The aerosol flux is sprayed onto the filler material in a controlled manner, allowing precise deposition of the required flux amount without the excessive adhesion that occurs with immersion dipping. This substitution of the application mechanism directly resolves the contradiction between achieving sufficient flux coating and minimizing flux waste.
2Ease of operation
If flux is applied manually to parent parts, then flux can be applied just prior to brazing, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent enables self-service flux application by pre-coating filler materials with flux during the manufacturing process. The filler materials are produced with integrated flux coatings, eliminating the need for manual flux application before brazing. This allows parts to be ready for brazing immediately upon receipt, significantly reducing production cycle time and labor requirements while maintaining ease of operation.
3Shape
If filler material is bent or shaped into preforms after flux application, then the preform shape is achieved, but the flux chips or cracks
Solution Approach 1:
The patent applies flux to the filler material in its original, unformed state before bending or shaping operations. By performing the flux coating operation preliminarily, before the material undergoes deformation, the flux coating is applied to a stable, non-stressed surface. This prevents the chipping and cracking that would occur if flux were applied after shaping, as the subsequent forming operations would disrupt the coating.
4Ease of manufacture
If custom machines are made for applying flux to individual parts, then flux can be applied to that specific part, but the cost of the machine increases
Solution Approach 1:
The patent employs a universal aerosol flux application system that can coat multiple different filler material shapes and sizes using the same equipment. The aerosol spray mechanism is adaptable to various geometries without requiring custom-designed machines for each part type. This multi-functional approach eliminates the need for expensive custom machinery while maintaining the ability to apply flux effectively to diverse parts.
5Ease of operation
If flux is applied to preforms, then the preform is ready for brazing, but the production cycle time extends
Solution Approach 1:
The patent applies flux to filler materials during the manufacturing process itself, before the materials are shipped or stored. By performing the flux coating operation in advance as part of production, the filler materials arrive at the brazing operation already prepared. This preliminary action eliminates the need for separate flux application steps at the brazing location, significantly reducing production cycle time while ensuring preforms are ready for immediate use.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a uniform flux coating with minimal waste, reduced production time, and the ability to coat multiple parts with the same machine, improving efficiency and reducing labor and material costs.
Implementation Method 1
The parts may then advance to a heating chamber to heat the parts with infrared light to promote better adhesion and curing of the flux
Implementation Method 2
The parts may then advance to a heating chamber to heat the parts with infrared light to promote better adhesion and curing of the flux
Implementation Method 3
the parts may advance to an ultrasonic flux spraying chamber where the parts may be sprayed with an ultrasonic sprayer configured to atomize a liquid flux solution
Data Source
AI summary
Systems and methods for evenly applying a flux coating to any number of different shaped parts with a single machine are described. The systems and methods provide advantages in that the flux coating may be applied accurately within 2% to 4% of desired thickness with 85% to 95% of the total yield of flux being applied, this minimizing waste. Thousands of parts may be batch treated with a single machine without operator input.