Soldering gun with U-shaped insertable terminal structure and tip having differing impedance layers

A soldering device comprising:

• a first terminal providing an energy feed path and a second terminal providing a energy return path the first and second terminals spaced a predetermined distance apart forming a cavity;
• and
• an elongate solder tip including first and second parallel leads each having a front and back end, the first and second leads joined together at the front ends forming a front end tip and an outer solder tip surface;
• the back ends of the first and second leads insertable and rigidly held inside the terminal cavity thereby electrically coupling the first lead to the first terminal and the second lead to the second terminal;
• each lead of the solder tip comprising a core of steel covered by a second layer of copper.

A solder tip for a solder gun, the solder gun generating a drive current, comprising:

• a core layer having an impedance that varies according to solder tip temperature;
• and
• a second layer surrounding the core layer having a relatively low impedance in comparison to the impedance of the core layer, the impedance of the second layer remaining substantially constant with variances in solder tip temperature;
• the combination of the first and second layers maintaining a constant solder tip temperature for variances in solder gun drive current.

A method for inserting and holding first and second solder tip leads having a center insulative material between a pair of terminals coupled to opposite polarities of a power supply in a soldering device, comprising:

• spacing the first and second terminals apart a given distance forming a terminal cavity;
• spacing the first and second leads of the solder tip apart a given distance;
• inserting the insulative material the first and second leads;
• pressing the first and second leads together compressing the insulative material while inserting the leads of the solder tip into the terminal cavity so that each lead makes electrical contact with a corresponding terminal;
• and
• releasing the leads so that the terminals hold the first and second leads in compression against the insulative material while the first and second leads remain separated.