Flexible TIG Torch Sleeve Structure for Bend Fatigue Resistance
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Solution Overview
Problem
Flexible TIG welding torches face local deformation and fatigue failure due to repeated bending deformations in the clad body and spiral connection wire during angle adjustments, leading to inefficiencies and safety risks in welding complex shapes or in narrow spaces.
Innovation Solution
A flexible TIG welding torch design featuring multi-layer protective sleeves with a mesh structure, including a fiberglass crimp net and adhesive layers, along with an auxiliary support wire and pipe, to disperse and absorb external forces, preventing local deformation and maintaining wire arrangement stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible connection portion with spiral connection wire and clad body is used to enable angle adjustment of the torch head, then the work range is expanded and welding efficiency is improved, but the spiral connection wire and clad body are repeatedly subjected to compression and tension forces causing local deformation and breakage
Solution Approach 1:
The patent applies nesting by placing the spiral connection wire inside the clad body, and further protecting it with multiple layers of protective sleeves (inner protective sleeve and outer protective sleeve). This nested structure allows the flexible connection to maintain its angle adjustment capability while protecting the inner wire from deformation and breakage through repeated bending cycles.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating multiple layers of protective sleeves (inner protective sleeve made of flexible material and outer protective sleeve) that preemptively absorb and distribute compression and tension forces before they can reach the spiral connection wire. This prevents local deformation and fatigue failure before they occur.
2Object-affected harmful factors
If the clad body is molded on the outer side of the spiral connection wire to protect it, then protection is provided, but the clad body penetrates or enters the space between arrangements of the spiral connection wire causing local damage
Solution Approach 1:
The patent uses nesting by placing the spiral connection wire inside the clad body, and further protecting it with multiple layers of protective sleeves (inner protective sleeve and outer protective sleeve). This nested structure allows the flexible connection to maintain its angle adjustment capability while protecting the inner wire from deformation and breakage through repeated bending cycles.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating multiple layers of protective sleeves (inner protective sleeve made of flexible material and outer protective sleeve) that preemptively absorb and distribute compression and tension forces before they can reach the spiral connection wire. This prevents local deformation and fatigue failure before they occur.
Data Source
AI summary
Disclosed is a flexible TIG welding torch having a torch body for performing an angle adjustment of a torch head with respect to a torch handle, wherein the torch body includes: a multi-array spiral wires having both ends connected to the torch head and the torch handle; a first protective sleeve supported in contact with outer sides of the wires and organized as a mesh structure; a second protective sleeve laminated as a mesh structure on an outer side of the first protective sleeve, and bonded onto an inner surface of a clad body of the torch body; and an adhesive layer impregnated into the mesh structures of the first and second protective sleeves to fix the first and second protective sleeves to each other, and support compressive and tensile stresses formed in the first and second protective sleeves.