Process For Flux Coating Braze Preforms And Discrete Parts

• US 20160303608A1
• Filed: 04/18/2016
• Published: 10/20/2016
• Est. Priority Date: 05/30/2013
• Status: Abandoned Application

• Current Assignee: Lucas-Milhaupt Incorporated (Steel Partners Holdings LP)
• Original Assignee: Lucas-Milhaupt Incorporated (Steel Partners Holdings LP)
• Inventors: Jossick, Daniel J.
• Application Number:
  US15/131,923
• Publication Number:
  US 20160303608A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B23K 1/203 Fluxing, i.e. applying flux onto surfaces
• CPC Class Codes: B23K 1/206 Cleaning
• CPC Class Codes: B23K 3/082 Flux dispensers; Apparatus for applying flux
• CPC Class Codes: B23K 35/0222 for use in soldering, brazing B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/286 Al as the principal constituent
• CPC Class Codes: B23K 35/3613 Polymers, e.g. resins
• CPC Class Codes: B23K 35/362 Selection of compositions of fluxes B23K35/365, B23K35/368 take precedence
• CPC Class Codes: B23K 35/404 Coated rods; Coated electrodes

Abstract

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.

Claims

1. A method of applying a flux coating on a plurality of parts for a brazing operation comprising:

tumbling the parts in a tumbling drum with a controlled atmosphere including a user definable temperature and humidity within the tumbling drum;

cycling the parts through a coating cycle comprising;

spraying a flux from at least one nozzle within the tumbling drum during the tumbling for a user defined period of time;

coating the parts with flux with a uniform thickness;

tumbling the parts following the user defined period of time to cure the flux to a desired hardness; and

repeating the coating cycle for a plurality of repetitions wherein the uniform thickness of coating on the parts is uniformly increased with each coating cycle.

2. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising providing an acrylic resin binder with an iso-butyl methacrylate polymer.

3. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 2, further comprising mixing polyethylene carbonate with the binder.

4. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising coating the parts up to 0.015 in (3.81 mm) thick while maintaining the uniform thickness within 2% of the total weight of the part.

5. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising spraying the flux from a nozzle with an opening of 0.05 in (12.7 mm) to 0.08 in (20.32 mm).

6. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising circulating the atmosphere within the tumbling drum with exhaust ducts.

7. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising adhering 85% to 95% of the sprayed flux to the parts.

8. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising agitating the parts within the drum with at least one agitator during tumbling.

9. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising spraying a sealant over the parts and flux.

10. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising setting the parts on a conveyor that transports the parts into an enclosure with a plasma cleaning chamber, a heating chamber, and an ultrasonic flux spraying chamber.

11. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 10, further comprising plasma cleaning the parts in the plasma cleaning chamber to remove contaminants allowing a proper adhesion of the flux coating to the parts.

12. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 11, further comprising heating the parts after plasma cleaning in the heating chamber to a desired temperature.

13. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 12, further comprising spraying the parts after heating in the ultrasonic spraying chamber with an ultrasonic sprayer configured to atomize a liquid flux solution and coat a single side of the parts with the flux coating and leaving an opposing side of the part free of the flux coating.

14. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 10, further comprising adjusting a speed of the conveyor to dry the parts to a desired moisture content.

15. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, further comprising spraying one of a metal and an alloy on the flux coated parts, thus eliminating a need for a filler metal application during a brazing procedure.

16. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 1, wherein the uniform thickness of the coating on the parts is within 2% of a desired thickness.

17. A method of applying a flux coating on a plurality of parts for a brazing operation comprising:

spraying a flux from at least one nozzle within a tumbling drum during a tumbling operation for a user defined period of time;

coating the parts with the sprayed flux with a uniform thickness;

tumbling the parts following the user defined period of time; and

curing the flux to a desired hardness.

18. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 17, further comprising:

coating the parts with the cured flux up to 0.015 in (3.81 mm) thick; and

maintaining the uniform thickness within at least one of 2% of the total weight of the part and 2% of a desired thickness.

19. The method of applying a flux coating on a plurality of parts for a brazing operation of claim 17, further comprising:

mixing an acrylic resin binder with an iso-butyl methacrylate polymer with the flux; and

mixing a polyethylene carbonate with the binder.

20. A method of applying a flux coating on a plurality of parts comprising:

spraying a flux from at least one nozzle with an opening of 0.05 in (12.7 mm) to 0.08 in (20.32 mm);

tumbling the parts for a user defined period of time within a tumbling drum;

coating the parts with the sprayed flux to a uniform thickness;

curing the flux to a desired hardness by circulating an atmosphere within the tumbling drum with exhaust ducts;

maintaining the uniform thickness within at least one of 2% of the total weight of the part and 2% of a desired thickness; and

adhering 85% to 95% of the sprayed flux to the parts.