Heating tool

7) A heating tool comprising:

• a cartridge including heater assembly, sleeve and tip, said tip having a hollow cylindrical proximal end, a middle section having an axial bore, and a distal end;
• said heater assembly including a heater coil having a proximal end wire and an end wire extending distally from said heater coil to a thermocouple, said heater coil secured in said hollow cylindrical proximal end of said tip with an dielectric insulating adhesive and said thermocouple secured within and press-fit into intimate contact with said axial bore of said middle part of said tip;
• a return wire extending from said thermocouple through said heater coil to a proximal end of said cartridge;
• said return wire formed from a nickel or nickel alloy material and said heater coil and end wire formed from an iron-chromium alloy, said return wire welded to said end wire to form a bimetallic thermocouple;
• a connecting wire attached to said proximal end wire of said heater coil, said connecting wire having a diameter between 0.8 mm and 1.2 mm and said proximal end wire of said heater coil having a diameter between 0.2 mm and 0.45 mm.

8) A heating tool formed by the process steps of:

• argon welding a nickel or nickel alloy return wire to an iron-chromium alloy wire to form a thermocouple;
• inserting said return wire through an insulation tube;
• wrapping said iron-chromium alloy wire around said insulation tube to form a heater coil;
• coating said heater coil with a dielectric insulating adhesive;
• forming a tip from copper to have hollow cylindrical proximal end, a middle section having an axial bore, and a distal end;
• inserting said thermocouple into said axial bore of said middle section of said tip and said heater coil into said cylindrical proximal end of said tip;
• press processing said middle section of said tip to deform said middle section and said thermocouple within said axial bore of said middle section;
• and
• inserting said cylindrical proximal end of said tip into a sleeve.