Denso Corporation

Harima Chemicals, Incorporated

Koji Onouchi

Hiroshi Ogawa

Ichiro Taninaka

Tsuguharu Shimpo

Masafumi Takahashi

Hiroki Tarui

Shouei Teshima

The purpose of the present invention is provide a method of forming a flux layer on an aluminum plate member, wherein a heating step for drying after a spray-coating of a flux composition can be omitted. The invention relates to a flux layercomposed of solid constituents of 5-25 g/mformed on a surface of an aluminum plate member, by spray-coating a flux composition from a nozzleto the plate memberwith a thickness of 0.2-1.6 mm, which was press-molded and heated for degreasing in a heat-degreasing oven, while a temperature of the plate memberis kept from 120 to 180&#xb0; C. under the remaining heat after completing a heating step for degreasing, and naturally drying for volatilizing volatile constituents of the flux composition utilizing the remaining heat.

Method of forming a flux layer on an aluminum plate member

For integrally bonding a first member and a second member made of copper or a copper alloy by brazing, a paste brazing material composed essentially of copper (Cu), tin (Sn), nickel (Ni) and phosphorus (P) is beforehand applied to at least one of the first and second members. A base material is exposed at the whole or a part of a contact portion between the first and second members. Thereafter, the first and second members are assembled at a predetermined position, and heated at a temperature in a range of 600&#xb0; C.-800&#xb0; C. within a reducing atmosphere furnace. By the brazing method, an oxide film on the surface of the base material can be sufficiently removed, so that the paste brazing material can smoothly flow on the surface at the contact portion.

Brazing method

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Gamagori, Japan

Koji Onouchi