Solder heating system

This invention provides a system capable of melting solder and removing the melted solder from a substrate. The heating system includes a desoldering tool having at least two handles, a first handle and a second handle. This way, an operator may grip the first handle or the second handle depending on the operator's preference of gripping the desoldering tool. The first handle has a cavity adapted to releaseably receive a storage where the melted solder can be deposited and stored. The storage may have a divot adapted to receive a key from the first handle so that the storage may be orientated in a predetermined position relative to the cavity. The cavity in the first handle is exposed so that the storage can be readily inserted or replaced. This allows the operator to easily replace and maintain the desoldering tool without a significant downtime. The first handle is adapted to receive a heater cartridge having a transition section to couple the leading section and the electrical cartridge in a staggered manner. This configuration allows the leading section to have a shortened channel that is substantially straight and aligned with the passage formed within the first handle to minimize the resistant to flow of the melted solder through the channel which is then deposited into the storage.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to a heating system for removing solder from a substrate such as a circuit board. In particular, the heating system is directed to a desoldering tool that provides a tip for melting solder and retrieving the melted solder to a replaceable storage for retaining the solder and providing operators with different options in gripping the desoldering tool.

2. General Background and State of the Art

Desoldering tools provide heat and vacuum source to a tip in order to melt the solder on a substrate and retrieve the melted solder through the tip. Internally, the desoldering tool has a solder collection chamber where the melted solder is deposited for temporary storage. In addition, the solder collection chamber is provided with a filter to remove the flux from the vapor that accompanies the melted solder so that filtered vapor may be vacuumed away to the vacuum source without clogging the internal mechanism of the desoldering tool. As the melted solder quickly fills the solder collection chamber, the passage to the vacuum source can clog up. This can shorten the desoldering operation and require frequent cleaning or changing of the solder collection chamber. In addition, the solder collection chamber may be integrated into the desoldering tool in such a way that the desoldering tool may need to be disassembled in order to replace or clean the solder collection chamber. This adds to the downtime of the desoldering operation and increases the chance that the desoldering tool is reassembled improperly. The frequent exchange or cleaning of the solder collection chamber also adds to the cost of operating the desoldering tool because of the expense associated with the solder collection chamber.

The desoldering tools are also provided with one grip handle so that operators are limited in the way they can grip the desoldering tools. For example, some soldering tools are provided with a pistol grip while other soldering tools are provided with an elongated housing with a grip on one end. Operators, however, may find that one type of a grip may be more ergonomically comfortable than others. In a large production facility where one type of a grip is provided, some operators may find that the grip is comfortable while many others may find that the same grip is uncomfortable. As such, there still is a need for an improved desoldering tool to efficiently clean or replace the solder collection chamber and provide a grip that is ergonomically comfortable to a variety of operators.

INVENTION SUMMARY

This invention provides a heating system capable of melting solder and removing the melted solder away from a substrate. The heating system includes a desoldering tool having at least a first handle and a second handle. Dividing the desoldering tool into two handles allows an operator to use the desoldering tool in two ways. One way is to operate the first handle independently without the second handle. Another way is to couple the second handle tangentially to the first handle so that an operator can grip the second handle like a pistol. The desoldering tool offers two ways to grip the tool so that operator can grip the first handle or the second handle depending on the operator's preference.

The first handle has a front end and a back end. Along the front end, the first handle is adapted to receive a heater cartridge. The heater cartridge has a leading section with a tip with a channel within the leading section to convey the vacuum source to the tip. In the back end, the first handle receives a power source and a vacuum source, where the power is transmitted to a heater, adjacent to the tip, to convert the power to heat in order to heat the tip. A passage between the vacuum source and the front end of the first handle conveys the vacuum source to the channel within the leading section. This allows the tip to heat the solder and retrieve the melted solder with the vacuum source provided through the channel formed within the leading section. To minimize the resistance to flow of the melted solder, the length of the channel may be minimized and the channel may be substantially straight. In addition, the temperature along the channel may be substantially constant.

To operate the desoldering tool, the first handle may have a first trigger and the second handle may have a second trigger. When only the first handle is used, the first trigger may be used to turn on or off the vacuum source to the tip. When the second handle is used, the second handle may be tangentially coupled to the first handle in such a way that the second trigger is mechanically coupled to the first trigger so that actuation of the second trigger activates the first trigger, which in turn turns on or off the vacuum source to the tip. As such, the first handle may be used independently as a desoldering tool, depending on the working environment and the operator's preference. Optionally, the second handle may be coupled to the underside of the first handle to turn on or off the desoldering tool using the second trigger located on the second handle.

Once the desoldering tool is in operation, the power to the heater may be provided while actuation of the first trigger or the second trigger may turn on or off the vacuum source to the tip. That is, the power provided to the heater may be monitored independently from the operation of the vacuum source so that the heater may provide sufficient heat to the channel to maintain the solder in a melted state so that the solder may flow through the channel.

The first handle may have a cavity adapted to releaseably receive a storage, where the melted solder through the channel can be deposited and stored. The storage may include a filter to capture the dust or vapors from the melted solder that may clog up the passage to the vacuum source in the first handle. The storage may have a divot adapted to receive a key from the first handle so that the storage may be orientated in a predetermined position relative to the cavity. The cavity in the first handle is exposed so that the storage can be readily inserted or replaced. This allows the operator to easily replace and maintain the desoldering tool without significant downtime.

Besides the leading section, the heater cartridge may have an electrical cartridge that couples to the power source to provide power to the heater adjacent to the tip. The heater cartridge has a transition section to couple the leading section to the electrical cartridge so that the longitudinal axis of the leading section is staggered with the longitudinal axis of the electrical cartridge. Such configuration allows the leading section to have a shortened channel that is substantially straight and aligned with the passage formed within the first handle to minimize the resistance to flow of the melted solder and provide an efficient path for the vacuum source. The diameter of the channel may be greater away from the tip to minimize the resistance to flow of the melted solder. In addition, the heater and the leading section may be integrated by bonding the two with ceramic material. This is done to block out air gaps to improve the conduction path from the heater to the tip of the leading section. By improving the conduction or heat transfer from the heater to the tip, the leading section may have a better thermal recovery to rapidly heat the leading tip and the channel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1illustrates a heating system show generally at10including a first handle12adapted to releaseably couple to a storage14, a heater cartridge16, and a second handle18. The first handle12has a cavity20that may be formed near the heater cartridge16. To engage the storage14within the cavity20, the first handle12may have a back holder22that may move between a first position and a second position. In the first position, the length of the cavity20may be longer than the length of the storage14along the longitudinal direction of the first handle12; whereas in the second position, the length of the cavity20may be similar or slightly less than the length of the storage14. As such, when the back holder22is in the first position, the storage14may be inserted or removed from the cavity20. To engage the storage14within the cavity20, the back holder22may be moved from the first position to the second position so that the storage14may be held within the cavity20.

As illustrated inFIG. 2, the first handle12has a first opening24and a second opening26adapted to receive the pipe28and the electrical cartridge30from the heater cartridge16, respectively. The electrical cartridge30has a contact end32that is adapted to electrically couple to the power line34provided to the first handle12. The heater cartridge16has a channel36formed between the tip38and the pipe28. Once the heater cartridge16and the storage14are assembled with the first handle12, the vacuum source40is connected to the channel36such that the vacuum may be provided at the tip38.

The first handle12may also have an engagement member42adapted to releaseably couple to the second handle18. The heating system10may be used or without the second handle18depending on the operator's preference. Once the desoldering tool is in operation, the power from the power line34may be provided to the heater cartridge16for heating the solder. The first handle12may have a first trigger43that may be activated and deactivated to turn on or off the vacuum source, respectively, to the tip of the heater cartridge16. The second handle18may be releaseably coupled to the first handle12through the engagement member42as illustrated inFIG. 2. The second handle18may be tangentially coupled to the first handle12so that the second handle may be gripped like a pistol. The second handle18may be releaseably coupled to the first handle in a variety of orientations to allow for comfortable grip to an operator. The second handle18may have a lock66that engages with the receptor64formed within the first handle12to lock the first handle12and the second handle18together. The second handle may be provided with a second trigger46that is mechanically coupled to the first trigger43such that when the second trigger46is activated, the first trigger43is activated as well. In other words, the second handle18may have a grip area23with the second trigger46so that a user may grip the heating system10like a pistol by gripping around the grip area23of the second handle18. In this way, a user may operate the first handle12independently as a desoldering tool by gripping the first handle12like a pencil, for example. Alternatively, the user may attach the second handle18to the underside of the first handle12to grip the grip area23of second handle18to hold the heating system10like a pistol depending on the user's preference. With the second handle18attached to the first handle12, the user may activate the second trigger46which in turn activates the first trigger43to provide the vacuum source to the tip38of the heater cartridge16.

The back holder22may have an outlet48that is coupled to the vacuum source40. The back holder22may be biased against a resistant member50to allow the back holder22to move between the first position and the second position.FIG. 2illustrates the back holder in the first position to allow the storage14to be inserted or removed from the cavity20. The storage14may be held between a first seal member52and a second seal member55. The first seal member52may be releaseably coupled to the front end54of the first handle12. The second seal member55may be releaseably coupled to the back holder22. Once the pipe28and the electrical cartridge30are inserted into the first opening24and the second opening26, respectively, the pipe28protrudes into the storage space56. A passage58may be formed along the storage space56, the second seal member55, back holder22, and so that the vacuum created along the outlet48may be conveyed to the tip38through the channel36.

The channel36formed between the tip38and the pipe28may be substantially straight to minimize the resistance to flow of the melted solder through the channel36. The temperature along the channel36may be maintained above the melting temperature of the solder to maintain the solder in a melted state. This way, melted solder removed through the channel36remains in the melted state as it flows from the tip38through the end of the pipe28. For instance, a portion of the pipe28may be surrounded by a heater60to conduct heat to the tip38to melt the solder to a liquid state and retrieve the melted solder through the channel36within the tip. The temperature along a portion of the channel36that is away from the heater60may be lower than the portion of the channel36that is closer to the heater60. To maintain the solder in the melted state along the entire length of the channel36, a portion of the pipe28that is away from the heater60may be covered with a conducting material62to conduct heat from the heater60to the portion of channel36that is away from the heater60. This way, the temperature along the channel36is maintained above a pre-determined temperature to maintain the solder in a melted state to remove the solder through the end of the pipe28and deposited into the storage space56. For example, the pipe28near the front end54of the first handle12may be surrounded by a bronze material to transfer the heat from the heater60to the portion of the pipe28that is away from the heater60.

FIG. 2illustrates that the channel36formed along the heater60and pipe28may be larger than the channel formed near the tip38. This may be provided to minimize the resistance to flow of solder through the pipe28and to provide a greater flow rate through the channel36formed within the tip38. To further minimize the resistance to flow of solder, the distance between the tip38and the end of the pipe28may be minimized. Accordingly, a combination of having a substantially constant temperature along the channel36that is short and straight provides for an efficient heater cartridge16that removes the melted solder from the tip38to the end of the pipe28. To shorten the length of the channel36and maintain it substantially straight, the heater cartridge16may have a staggered configuration as discussed below. In addition to having a substantially straight channel36, the passage58formed along the storage space56, the second seal member55and the back holder22may be substantially straight as well to minimize the resistance to the vacuum source between the outlet48and the storage space56. As the heater cartridge16wears out, it may be replaced. Optionally, just the tip38may be replaceable so that the heater60and the electrical cartridge30may be reused.

FIG. 2illustrates that the heater cartridge16may include a leading section17coupled to a transition section19. The electrical cartridge30is also coupled to the transition section19but the electrical cartridge30may be off-set with respect to the leading section17. Accordingly, the heater cartridge16may have a leading section17that is staggered with respect to the electrical cartridge30. Such configuration allows the channel36to be substantially straight and aligned with the passage58formed within the first handle12to minimize the resistance to providing vacuum from the vacuum source40to the channel36. Such configuration also reduces the distance between the tip38and the pipe28, and provides for a channel36that is substantially straight. The electrical cartridge30may be detectable from the transition section19so that the electrical cartridge30may be replaceable. The first and second seal members52and55may be releaseably coupled to the first handle12such that they too may be replaceable. Optionally, as the leading section17wears out, it may be removed from the transition section19and replaced with a new leading section.

FIG. 2illustrates that the first handle12may be utilized with or without the second handle18. The engagement member42may have a receptor64adapted to receive a locking member66from the second handle18. The second handle18may further include a hook68adapted to slide into a slot70formed within the engagement member42. To releaseably couple the second handle18to the first handle12, the hook68may be slid into the slot70as indicated by the direction arrow72. Once the second handle18is fully inserted into the engagement member42, the locking member66engages into the receptor64thereby locking the second handle18to the first handle12. The locking member66may be biased against a resisting member74to allow the locking member66to move between an engagement position and a releasable position. The locking member66may be coupled to a switch44to move the locking member66between the engagement position and the releasable position. The second trigger46may be coupled to a rod76which is biased by the resisting member78. Once the second handle18is fully engaged with the engagement member42, the free end of the rod76may be positioned against the first trigger43of the first handle12. As such, the actuation of the second trigger46causes the first trigger43to actuate thereby providing vacuum source to the tip38. To release the second handle18from the first handle12, the switch44may be lowered thereby disengaging the locking member66from the receptor64to allow the second handle18to move in the opposite direction of the direction arrow72. Once the hook68is disengaged with the engagement member42, the second handle18may be disengaged from the first handle12.

FIG. 2illustrates that the transition section19may be comprised of a first plate80and a second plate82with spacers84between the two plates to provide a gap86between the two plates. The gap86may be provided to insulate the second plate82from the thermal heat provided by the heater60. In addition, electrical conductor wires from the electrical cartridge30may be fed through the gap86and coupled to the appropriate leads in the leading section17. The first plate80may be a metal piece capable of withstanding high temperature. The second plate82may be formed from a plastic material capable of withstanding high temperature as well. The second plate82may have a sleeve83adapted to receive the electrical cartridge30. The sleeve83may extend further than the pipe28so that as the electrical cartridge30is inserted into the second opening26, the sleeve83may contact the second opening26before the pipe28made its contact with the first opening24. The sleeve83and the second opening26may have a predetermined configuration so that as the sleeve83is inserted into the second opening26, the sleeve83orientates the heater cartridge16relative to the first handle12. With the sleeve83orientating the heater cartridge16, the pipe28may be orientated with the first opening24as well so that pipe28may be inserted into the first opening24with minimal resistance or without damaging the first seal52. For instance, the sleeve83and the second opening26may have a square, oval, rectangular, or like configuration so that as the sleeve83is inserted into the second opening26, the sleeve83orientates the heater cartridge12relative to the first handle12.FIGS. 3 and 4illustrate the sleeve83and the second opening26having a square outer configuration to orientate the heater cartridge16.

FIG. 3illustrates the back side of the second plate82with the pipe28protruding through an opening85formed within the second plate82. In addition, the conducting material62may surround at least a portion of the pipe28that protrudes through the opening85as well. A space may be provided between the conducting material62and the opening85to minimize damage that may be caused due to excessive heat from the conducting material62to the second plate82.FIG. 3illustrates the electrical cartridge30protruding from the second plate82as well. The second plate82may further include teeth90adapted to engage with the front end54of the first handle12as described below.

FIG. 4illustrates the front end54having a first opening24and a second opening26. The first opening24may be formed within the first seal member52. The seal member52may also have a depression88adapted to receive the conducting material62with a gap to minimize the heat transfer from the conducting material62to the first seal member52. The front end54may also include notches92adapted to receive the teeth90protruding from the second plate82.

FIG. 5Aillustrates the pipe end28and the electrical cartridge30fully inserted into the first and second openings24and26, respectively. In addition, the storage14is engaged within the cavity20by the back holder22in the second position. As the heater cartridge16is inserted into the first handle12, the teeth90engage with the notches92to align the heater cartridge16with respect to the first handle12along with the sleeve83and the second opening26as discussed above. The teeth90may butt against the notches92to form a second gap94between the second plate82and the front end54to further insulate the front end54from the thermal heat from the heater60.

FIG. 5Aalso illustrates the first handle12having a button95that releases the heater cartridge16once the heater cartridge16is engaged with the first handle12.FIG. 5Billustrates an internal mechanism to hold the heater cartridge once the sleeve83is inserted into the second opening26of the first handle12. The button95extends from a hinge97with a large opening99adapted to receive the electrical cartridge30. The large opening99is sufficiently large so that the button95may be pushed perpendicularly relative to a longitudinal axis of the electrical cartridge. The button95may be pushed which in turn causes the hinge97to move away from the electrical cartridge. The sleeve83has a cavity87adapted to receive the hook101of the hinge97so that once the hook101is engaged with the sleeve83, the heater cartridge16is prevented from being pulled away from the first handle12. To release the heater cartridge16, the button95may be pushed thereby causing the hook101to release the sleeve83so that the heater cartridge may be pulled away from the first handle. Such mechanism ensures that the heater cartridge16does not pull away from the first handle unintentionally.

FIG. 6illustrates an exploded view of the storage14. The storage14may include a housing100having a first end102and a second end104with an opening between the two ends. The housing100may be adapted to receive a filter106within the second end104. The housing100may further receive a radiating member108so that the radiating member108and the filter106may be adjacent to one another. The radiating member108may have a U-shape configuration with a base110and a pair of legs112extending therefrom. The pair of legs112may be substantially planar so that once the melted solder comes into contact with any one of the legs112and the base110, they may conduct heat away from the melted solder to cool and solidify the solder onto the radiating member108. This way, the melted solder may be retained and stored within the storage14. In addition, the housing100may be made of transparent material so that the operator may visually detect whether the storage is full of solder or not. In terms of material, the housing, radiating member, and the filter may be made of a variety of materials. For instance, the housing may be made of paper, plastic, transparent plastic, glass, metal, etc. The radiating member may be made of aluminum, steel, and the like.

FIG. 7illustrates a cross-sectional view of the storage14illustrating that the base110of the radiating member108may be flush against the filter106. The radiating member108may be formed from a thin strip of a material and bent ninety degrees in two corners with respect to the base110to form the U-shape radiating member108. Depending on the length of the two legs112, the base110may be flush against the filter106or a gap may be formed. Having a gap between the base110and the filter106may provide additional passage for the vacuum provided through the vacuum source40to be provided at the tip38. In other words, having a gap between the base110and the filter106may minimize the resistance to flow of solder into the radiating member108. Even without a gap, however, the outer areas along the filter106, not against the base110, may provide sufficient passage to vacuum the solder through the tip and into the radiating member108.

FIG. 8illustrates the front view of the storage14with the filter106fitted into the second end104of the housing100and the radiating member108inserted into the housing100with the base110being adjacent to the filter106. The base110of the radiating member108may have a diagonal distance Bd that is substantially similar or slightly less than the inner diameter Hd of the housing100. As such, the radiating member108may fit snugly into the housing100. With the snug fit between the radiating member108and the housing100, the passages58are formed along the longitude direction of the housing100as illustrated inFIGS. 7 and 8. The passages58ensure that the vacuum created in the outlet48may be also provided at the tip38through the passages58within the storage14.

FIG. 8illustrates that cutouts114may be formed within the inner surface of the housing100so that the radiating member108may be inserted into the housing100in a predetermined orientation. In addition, as illustrated inFIG. 6, the second end104of the housing100may have a divot116adapted to receive a key118(as illustrated inFIG. 17) protruding from the second seal member55. The combination of the key118and the divot116allows the storage14to be inserted into the cavity20in a predetermined position or orientation relative to the cavity20. Accordingly, the combination of the cutouts114within the inner surface of the housing100and the divot116on the housing100may ensure that when the storage14is inserted into the cavity20, the pair of legs112are oriented in a predetermined direction so that the melted solder passing through the pipe28may generally fall on one of the legs.

FIGS. 9 through 13illustrate a variety of alternative radiating members108that may be used within the storage14for capturing the melted solder received through the pipe28.FIG. 9illustrates that the radiating members108may have a base110having a V-shaped configuration;FIG. 10illustrates the base110having a U-shape; andFIG. 11illustrates a base110having a W-shaped configuration. The radiating members108may be formed from a strip of metal and bent along the base to have a variety of configurations as illustrated inFIG. 7andFIG. 9throughFIG. 11. With the base110having a V, U, or W shaped configuration, as illustrated inFIGS. 9-10, respectively, a substantial portion of the filter surface may be exposed so that vacuum source created on the second end104of the housing100may be conveyed to the first end102of the housing100. In other words, with a small portion of the base110making contact with the filter106, the resistance to providing vacuum through the filter106is minimized.FIG. 12illustrates that a gap121may be formed between the base110of the radiating member108and the filter106. The gap121provides a clear passage for vapor from the pipe28to pass through the filter106where it is filtered so that cleaner fume or vapor may pass through the second end104of the storage14.FIG. 13illustrates a radiating member108that is curved like a sine wave so that as the melted solder lands on the radiating member108, the heat from the melted solder is quickly dissipated through the radiating member108. The curvature of the radiating member108substantially prevents the melted solder from making contact with the filter106.

FIGS. 14 through 16illustrate a variety cross-sectional views for the second seal member55to close the second end104of the housing100.FIG. 14illustrates that the enclosing side120may have a bevel edge122along the outer edge of the second seal member55to substantially seal around the outer circumference of the second end104of the housing100. Depending on the slope of the bevel edge122, the depth to which the enclosing side may engage within the housing100may vary. As the resisting member50pushes the second seal member55against the second end of the housing100, the enclosing side120may engage with the filter106which in turn causes the filter to engage or flush with the base110of the radiating member108. As discussed above, however, the pair of legs112of the radiating member108may be shortened to ensure that a gap may be formed between the base110and the filter106.

FIG. 15illustrates that the enclosing side120may have a step124and a bevel126along the outer circumference of the second seal member55. As the resisting member50pushes against the second seal member55, the bevel126may be inserted into the second end104of the housing100such that the bevel edge126properly aligns the second seal member55with the longitudinal axis of the housing100. In turn, the second end104may properly engage with the step124of the seal member55to form a seal between the two.

FIG. 16illustrates the enclosing side120of the second seal member55having a step124. Once the second seal member is engaged with the second end104of the housing100, the step124and a portion of the enclosing side may engage with the inner wall of the second end104to provide a seal between the second seal member55and the second end104of the housing100.

FIG. 17illustrates the second seal member55having a key118protruding from the sealing side120. The second end104of the housing100may have a divot116adapted to receive the key118so that the second seal member55may be properly orientated along the radial direction relative to the housing100. The combination of the key118and the divot116may be provided to ensure that the storage14is properly orientated within the cavity20once the second seal member55engages with the second end104of the housing100. The variety of configurations illustrated inFIGS. 14 through 16may be provided in the first seal member52such that the respective enclosing sides may be either symmetrical or non-symmetrical. In addition, the key118and the divot116combination may be provided on the first seal member52and the first end102of the housing, respectively.

FIGS. 18A and 18Billustrate that the second handle18may have a pin128that is adapted to move in and out of the second handle18.FIG. 18Aillustrates the pin128in a retracted position, andFIG. 18Billustrates the pin128in the extended position. The second handle18may be provided with a button130that is coupled to the pin128such that when the button130is moved from the retracted position as shown inFIG. 18Ato the protracted position as shown in18B, the pin128protrudes from the second handle18. The diameter of the pin128may be substantially similar or slightly less than the diameter of the channel in the tip38. As such, with the pin128in the protracted position, the pin may be inserted into the channel36of the tip38to remove the solder that may have solidified within the channel36. That is, the pin128may be used to clean the channel36to remove the unwanted solder that may be clogging the channel36.

FIGS. 19illustrates a heater cartridge remover132adapted to engage with the heater cartridge16to remove the heater cartridge from the first handle12when the heater cartridge is hot. The heater cartridge remover132has a holding wall133and a hook135with a space therebetween. The holding wall133and the hook135are configured to associate with the bottom side of the transition section19so that the space between the holding wall133and the hook135may receive the first plate80(FIG. 2) of the transition section19. With the first plate80between the holding wall133and the hook135, a user may hold onto a holding portion134of the remover132to pull the heater cartridge16away from the handle12or insert the heater cartridge16to the handle12. This way, a user may use the remover132to remove the heater cartridge16from the handle12while it is hot. When the heater cartridge remover132is not in use, the heater cartridge remover may be releaseably coupled to the second handle18or the first handle12so that the heater cartridge remover does not get misplaced.

FIG. 20illustrates a desoldering system shown generally at136for providing power and vacuum source to the heating system10. The desoldering system136includes a power source138that is communicably coupled to a desoldering control box140, which provides power and vacuum source to the heating system10. The power source138may be any one of pre-existing power sources that may be used to provide power to the soldering tool. For desoldering operations, the desoldering control box140may be communicateably coupled to the power source138, so that the control box140may control the power provided to the desoldering system as discussed below. For instance, the power source may be controlled by well known control system such as ON/OFF control and/or PID control, or power source as described in U.S. Pat. No. 6,563,087, which is hereby incorporated by reference into this application.

The desoldering control box140may control the supply of power and vacuum to the heating system10in the following ways. In general, the heater and the temperature sensor are located near the tip so that the temperature sensor may not accurately reflect the temperature along the entire length of the channel36. In particular, the pipe28may be located further away from the heater than the tip, so that there may be some time delay for temperature near the pipe28to rise near the temperature of the tip38. This means that although the tip38may be hot enough to melt the solder on a substrate, the temperature along the channel36may not be hot enough to maintain the melted solder from the tip38in a melted state along the entire length of the channel36. As such, solder may solidify within the channel and not pass through the other end of the pipe28.

FIG. 21illustrates a process in which the desoldering control box140may operate the heating system10to substantially prevent the solder from solidifying within the channel36. In step142, the desoldering control box140may monitor whether the desoldering tool10is being turned on or not. If the desoldering tool is being turned on in step144, the desoldering control box may delay the operation of the desoldering tool until the temperature within the channel36reaches a temperature such that the melted solder remain in the melted state so that the melted solder may flow through the channel36and towards the pipe28. After the delay in step146, the control box140may allow the operation of the desoldering tool by providing vacuum source to the tip when the first trigger43or the second trigger46is activated. This may be done for example by providing power to the heater until the substantial portion of the channel36reaches a predetermined temperature but not providing vacuum source to the tip until the predetermined temperature along the channel36is reached. The delay in step146may be between about fifteen and about thirty seconds.

Once the desoldering tool is in operation, in step148, the control box140monitors the operation to determine whether the desoldering tool10is being turned off or not. If the desoldering tool is being turned off, in step150, the control box140delays turning off the power and vacuum to the desoldering tool until the channel36is substantially free of solder. This way, remaining solder does not clog the channel36which may hinder the next operation. In step152, the desoldering tool is turned off after the delay in step150. The delay may be between about fifteen and about thirty seconds before turning off the desoldering tool. In step154, if the desoldering tool is not being turned off, the control box140monitors the temperature of the tip and provides sufficient power to the heater to maintain the predetermined temperature. Once the desoldering tool10is turned off, the control box140may proceed to the steps150and152to turn off the desoldering tool10.

While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. For instance, the heating system10may be adapted for a soldering tool rather than as a desoldering tool as discussed above. That is, the first handle12can be adapted as a soldering iron with a releasable heater cartridge16. A user may grip the first handle along the back end of the first handle, which is away from the heater cartridge, for a soldering operation without the need for a vacuum source. If the user prefers a pistol grip, the user may couple the second handle18to the first handle12to grip around the second handle18. The second handle may couple to the first handle in a variety of ways and in a variety of orientations. For example, the second handle may be snapped onto the first handle and the second handle may be tangential relative to the first handle such that the first handle is substantially perpendicular to the first handle once the first and second handles are coupled together. In addition, once the first handle is coupled to the second handle, the orientation of the second handle may be adjusted relative to the first handle so that a user may grip the second handle in a comfortable manner. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.