Abstract:
The present disclosure comprises methods, apparatus, components, and techniques for soldering. A soldering tool includes opposing jaw pieces adapted to grip and/or compress work pieces while applying heat. The work pieces can be heated to a temperature at or above the melting point of a solder material, whereupon the solder may be melted and applied at the work pieces. The soldering tool may be removed from the work pieces, thereby allowing the solder to solidify and form a soldered joint. Soldering tools may be powered by portable, rechargeable, and/or detachable battery packs that are readily accessible and commonly used for a wide variety of hand-operated power tools.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 USC §119 to U.S. Provisional Patent Application Ser. No. 61/807,166, filed on Apr. 1, 2013, and titled “The Crolder-Soldering Iron that Crimps,” the entire contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND 
     Technical Field 
     The present disclosure relates generally to a soldering hand tool. 
     Description of Related Art 
     In general, soldering is carried out by securing two work pieces together and joining the two work pieces by melting a solder material between the work pieces. Typical soldering material is an alloy having a melting point lower than the work pieces being joined. Soldering tools may be used to heat up the work pieces and melt the soldering material. Soldering tools are embodied in a variety of configurations. Examples of hand-soldering tools include a soldering iron, soldering gun, soldering pen, soldering torch, and the like. Such tools commonly have an electrically-heated soldering tip, which may routinely be used to heat the two or more work pieces to be joined to form a soldered joint. Soldering may be used in electronics, plumbing, metalwork including jewelry, and other fields where joining two or more items, such as metal items, is desired. 
     In electronics soldering, a soldered joint preferably provides electrical conductivity across the joint and a sufficiently strong mechanical connection to maintain the soldered work pieces together. In other types of metal-working soldering, a soldered joint may preferably exhibit sufficient mechanical strength to hold the soldered work pieces in place with each other. 
     Work pieces can be secured to each other at a joint by soldering. If the two work pieces are wires, the wires may be twisted together. The work pieces can then be heated. In some forms, a flux material is applied to the heated work pieces. The solder material can then be applied to the heated work pieces, thereby causing the solder to melt and flow around the joint. The heat source may then be removed, while still holding the work pieces together until the solder metal has solidified and the soldered joint is stable. Work pieces are held together until the solder at the joint has sufficiently cooled. In some cases, if the work pieces move relative to each other while the solder is not cooled enough, the resulting joint may crack or otherwise become defective. Such a defective joint may be referred to as a “dry joint.” A dry joint may be mechanically weak and/or exhibit high electrical resistance relative to an ideal soldered joint 
     SUMMARY 
     In one embodiment, an apparatus for soldering two or more work pieces together is disclosed. The apparatus has a jaw, a heating element at the jaw, a power source, and a handle. The jaw includes a first jaw piece and a second jaw piece. The heating element is positioned at the jaw. The power source can provide an electrical current to the heating element. The handle has a first handle piece and a second handle piece. The first handle piece is rigidly connected to the second jaw piece, forming a first assembly. The second handle piece is rigidly connected to the first jaw piece, forming a second assembly. The first assembly is joined to the second assembly at a pivot. 
     The present disclosure will now be described more fully with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred or particular embodiments specifically discussed or otherwise disclosed. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only so that this disclosure will be thorough, and fully convey the full scope of the invention to those skilled in the art. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  depicts an isometric projection of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 2  depicts a side view of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 3  depicts an end view of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 4  depicts a top view of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 5  depicts an exploded front-side view of heating elements of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 6  depicts an exploded rear-side view of heating elements of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 7  depicts an exploded view of gripping elements of a soldering tool according to an embodiment of the present disclosure; 
         FIG. 8  depicts a side isometric projection of an open soldering tool according to an embodiment of the present disclosure; 
         FIG. 9  depicts a front isometric projection of an open soldering tool according to an embodiment of the present disclosure; and 
         FIG. 10  is a block diagram illustrating one embodiment of the present disclosure. 
     
    
    
     Corresponding reference characters indicate corresponding components throughout the several views of the drawings Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure. 
     DETAILED DESCRIPTION 
     In the following description, reference is made to exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the spirit and scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense. 
     Reference throughout this specification to “one embodiment,” “an embodiment,” “one example,” or “an example” means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “one example,” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. 
     Embodiments of the present disclosure provide methods, apparatus, components, and/or techniques for soldering two or more work pieces together. Referring to  FIG. 1 , an embodiment of the present disclosure comprises a soldering tool  100 . According to embodiments, soldering tool  100  may allow a user to solder two or more work pieces together while securing the work pieces in place with each other. As will be described in further detail, soldering tool  100  may be used to create soldered joints faster and easier than other known methods, leading to a higher degree of repeatability, which may result in increased efficiency and lower production costs. 
     One embodiment of soldering tool  100  comprises jaw  110  and handles  120 . Soldering tool  100  further comprises two levers joined at a pivot  130 . Jaw  110  is formed by one end of levers and handles  120  are formed by the other end of levers, opposite the pivot  130  from jaw  110 . Jaw comprises two jaw pieces  112  and  114 , each jaw piece  112  and  114  comprising an end section of the levers. Jaw pieces  112  and  114  comprise soldering surfaces. In an embodiment, soldering surfaces comprise longitudinal ridges  118  and at least one corresponding opposing groove  119  on at least one jaw piece  112  and/or  114 , such that as jaw  110  is closed, ridge  118  nestles into corresponding groove  119 . In alternative embodiments, soldering surfaces comprise other configurations adapted to secure work pieces to be soldered together. In one embodiment, groove  119  comprises a longitudinal channel from a front surface of jaw piece  114  along the length of jaw piece  114 . 
     In one embodiment, soldering surfaces comprises lateral notch  117 . Notch  117  provides a lateral through-hole in jaw piece  114 , into which work pieces may be positioned and held for soldering. According to embodiments, notch  117  passes through one or more longitudinal ridges  118 . 
     In embodiments, jaw pieces  112  and  114  comprise a material having relatively high thermal conductivity. In one embodiment, jaw pieces  112  and  114  are made of iron. In embodiments, jaw pieces are nickel or chrome plated. In embodiments, jaw pieces  112  and  114  comprise an iron-plated copper core. 
     In an embodiment, handles  120  comprise a thermal and electrical insulating material. Embodiments comprise handle gripping surfaces ergonomically conformed to a typical user&#39;s hand shape. Handles  120  comprise a first handle piece  122  and a second handle piece  124 . 
     In embodiments, pivot  130  comprises two pivot disks  132  and  134  joined by a pivot pin  136 . Pivot disks  132  and  134  rotate about pivot pin  136  as a user opens and closes handles  120 , thus opening and closing jaw  110 . In embodiments, a spring (not shown) can apply an opening force to handles  120  and/or jaw  110 , which can be countered by the user squeezing handles  120  to close handles  120  and jaw  110 . According to various embodiments, handles  120  are relatively longer than jaw  110 . 
     In one embodiment, first handle  122 , pivot disk  132 , and jaw piece  114  are rigidly connected, forming a first tool assembly. In the same embodiment, second handle  124 , pivot disk  134 , and jaw piece  112  are rigidly connected, forming a second tool assembly. When pivot disks  132  and  134  are connected at pivot pin  126 , the first and second tool assemblies form a lever mechanism, by which a user may close jaw  110  and apply a crimping force on an object within jaw  110  by closing and squeezing handles  120 . 
     Embodiments of soldering tool  100  comprise a heat source at heat jaw  110 . Referring now to  FIGS. 5 and 6 , in an embodiment, heating elements  140  are disposed within jaw pieces  112  and  114 . In one embodiment, heating elements  140  comprise ceramic resistive heating elements adapted to generate heat in response to electric current flow therethrough. In another embodiment, heating elements  140  comprise metal resistive heating elements. In another embodiment, heating elements  140  comprise a torch heating element, for example a propane torch. In other embodiments, heating elements  140  may create heat through any other means. 
     According to embodiments, jaw  110  comprises one or more insulating covers  150  to reduce the risk of burns to the user or other objects from the heated jaw pieces  112  or  114 . In various embodiments, cover  150  fully or partially encompasses jaw pieces  112  or  114 . Cover  150  comprises vent slots  155  to prevent jaw  110  from overheating while soldering tool  100  is in use. 
     Referring now to  FIG. 8 , embodiments of the present disclosure comprise power connector port  160 . In the embodiment depicted, power connector port  160  comprises an input for receiving electric power from a power source. In some embodiments, the power source comprises a battery pack in electrical communication with power connector port  160 . In one embodiment, the battery pack connects to power connector port  160  via a connector cord having a Dean&#39;s connector. In other embodiments, other types of connections, sockets, and the like are used to supply an electric current to tool  100 . According to various embodiments, the battery pack is a rechargeable and/or interchangeable battery pack such as those commercially available for hand-operated power tools. In other embodiments, other types of electrical connectors are used to provide electrical connection between a power source and power connector port  160 . In one embodiment, a battery pack includes a clip for mounting to a user&#39;s belt or other clothing. In such an embodiment, the connector cord is long enough to allow free movement of soldering tool  100  in the user&#39;s hand while the battery is mounted on the user&#39;s belt. Alternative embodiments comprise a plug to connect to an alternating current (AC) power source such as a wall outlet. One embodiment of a soldering tool may be switched between various forms of electrical power. In some embodiments, tool  100  may be supplied electric power from a generator. 
     Referring now to  FIG. 10 , various embodiments of the present disclosure comprise heating element control circuitry  1000 . Heating element control circuitry  1000  comprises heating element  140 , heating element driver  1010 , temperature controller  1020 , and battery  1030 . In an embodiment, temperature controller  1020  comprises a microprocessor and computer-readable instructions and data stored on a memory to direct current flow from battery  1030  to heating element driver  1010 , which may then drive heating element  140  at a predetermined current or other parameter. In another embodiment, a user may select a desired temperature level. In response, temperature controller  1020  may direct heating element driver  1010  to apply a current level that corresponds to the user-selected temperature level. Power may be cycled on and off at heating element driver  1010  to maintain temperature sufficiently above a target temperature while not exceeding a maximum desired temperature. For example, in embodiments, it may be desirable to maintain the temperature of the jaw  110  above the melting point of solder material but below the melting point of the work pieces to be soldered. In one embodiment, upon powering on, heating elements  140  are powered on until a set target temperature is met. Upon meeting a target temperature, less current may be passed through heating elements  140  in order to maintain temperature at the target. 
     Some embodiments additionally include feedback loop  1050 . Feedback loop  1050  comprises temperature sensor  1060  and temperature sensor driver  1070 . Temperature sensor  1060  is adapted to detect the temperature of heating element  140  and transmit a signal to temperature sensor driver  1070  that corresponds to the measured temperature. Temperature sensor driver  1070  can subsequently transmit a signal to temperature controller  1020  relating the measured temperature. As temperature data is received by temperature controller  1020 , a comparison between the measured temperature and a target temperature may be carried out. If the measured temperature is less than the target temperature, the heating element driver  1010  may be directed to increase power to heating element  140  until the target temperature is reached or exceeded. If the measured temperature is greater than the target temperature, the heating element driver  1010  may be directed to power down heating element  140  until the measured temperature falls below or near the target temperature. 
     In one embodiment of the present disclosure, an indicator light is adapted to activate while electrical current is being applied heating element  140 , so that the user may know that jaw  110  is heating up. In another embodiment, an indicator light activates whenever jaw  110  is above a threshold temperature, so that the user may know that the jaw  110  is hot enough to solder. In one embodiment, a temperature readout is displayed to the user. 
     In operation, solder tool  100  can assist a user to quickly and conveniently solder two or more work pieces together. The heating elements  140  and/or jaw pieces  112  and  114  of solder tool  100  may be heated in order to melt solder onto two or more work pieces to be joined. In embodiments, the jaw pieces  112  and/or  114  may be heated to a temperature slightly higher than the melting point of the solder to be used. The work pieces to be joined may then be secured together between the heated jaw pieces  112  and  114 . In one embodiment, the work pieces to be joined may pass or partially pass through notch  117  before the user closes the jaw  110 . The user may squeeze the handles  120  together while the work pieces are within the jaw  110  to compress the work pieces. 
     Conductive heating from jaw pieces  112  and/or  114  then heats the work pieces to a temperature slightly higher than the melting point of the solder. The compression may be applied to the work pieces while heat is applied. The user may then apply solder at the junction between the work pieces. The solder can melt from the heat of the work pieces to be joined. Melted solder may then be drawn around the work pieces at the joint by capillary action. The user may then release the compression pressure of the jaw  110 , open the jaw  110 , and move soldering tool  100  away from the newly-formed joint, allowing the solder to cool and fully solidify. As one of ordinary skill in the art having the benefit of this disclosure, various solder types and alloys may be used with soldering tool  100 . 
     Although the present disclosure is described in terms of certain preferred embodiments, other embodiments will be apparent to those of ordinary skill in the art, given the benefit of this disclosure, including embodiments that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the spirit and scope of the present disclosure.