Welding Torch Nozzle Insert for Slip-On and Screw-On Attachment

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Solution Overview

Problem

Conventional arc welding torches are limited to a single nozzle attachment method, requiring manufacturers and users to maintain multiple parts to accommodate different attachment preferences, leading to increased inventory management and complexity.

Innovation Solution

A nozzle assembly design that allows for both slip-on and screw-on attachment methods, utilizing a nozzle insert with a frictional engaging surface and threaded surface to securely attach to various gas diffuser assemblies, reducing the need for separate nozzles and simplifying inventory management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional nozzles and torches are configured for only one attachment method, then the attachment is simple and reliable, but manufacturers and users must maintain a large number of different parts to accommodate different attachment preferences and requirements

Engineering Contradiction:

Improveattachment method compatibilityVSAvoidnumber of different parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The gas diffuser assembly is designed with dual attachment features: a frangible weld zone for weld-on attachment and external threads for screw-on attachment. This allows a single gas diffuser assembly to accommodate multiple attachment methods, eliminating the need for separate gas diffuser assemblies for each attachment type and reducing the number of parts that must be maintained.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If manufacturers keep track of a large number of different parts for different attachment methods, then proper attachment and operation can be ensured, but inventory management complexity and costs increase

Engineering Contradiction:

Improveproper attachment assuranceVSAvoidinventory management complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The nozzle assembly is designed with dual attachment features: a frangible weld zone for weld-on attachment and external threads for screw-on attachment. This allows a single nozzle assembly to accommodate multiple attachment methods, eliminating the need for separate nozzle assemblies for each attachment type and reducing the number of parts that must be maintained.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If a single gas diffuser assembly supports multiple attachment methods, then inventory needs are reduced and versatility is improved, but the design complexity of the gas diffuser assembly increases

Engineering Contradiction:

Improveattachment method compatibilityVSAvoidgas diffuser assembly design

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The gas diffuser assembly is designed with distinct functional zones: a frangible weld zone for weld-on attachment and external threads for screw-on attachment. This segmentation allows each attachment method to have its own dedicated feature, simplifying the design process while achieving multi-functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the gas diffuser assembly are designed with different properties: the frangible weld zone is designed for welding attachment while the external threads are designed for screw-on attachment. This local differentiation allows each region to optimize for its specific attachment method while the overall assembly achieves versatility.

Inventive Principle:

Principle #3Local quality

4Ease of operation

If conventional nozzles use a single attachment method, then the nozzle design is simple, but operators with different preferences cannot be accommodated without additional parts

Engineering Contradiction:

Improveoperator preference accommodationVSAvoidnozzle design

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables a single nozzle to be used with multiple attachment styles, significantly reducing inventory needs and simplifying attachment processes, while providing secure retention through dual engagement features, enhancing operational efficiency and reducing the risk of disengagement during welding operations.

Implementation Method 1

The frangible weld zone is configured to attach the gas diffuser assembly to the nozzle assembly

Methodology Applied

Scientific EffectArc welding: Welding

Implementation Method 2

The gas diffuser assembly may include external threads configured to engage complementary internal threads of the nozzle assembly

Methodology Applied

Scientific EffectThreaded engagement: Screw

Data Source

PatentUS11192202B2Gas diffuser assemblies for nozzle assemblies having multiple attachment methods

Publication Date: 2021.12.07 ILLINOIS TOOL WORKS INC

AI summary

A welding torch having a nozzle assembly with multiple attachment methods is disclosed. The nozzle assembly includes a nozzle shell, an electrically insulating sleeve, and a nozzle insert. The nozzle insert is configured for attachment to gas diffuser assemblies with different attachment mechanisms (e.g. a slip-on mechanism relying on frictional force, and/or screw-on mechanism relying on torque).