Trailing Gas Nozzle Channels for Uniform Weld Shielding
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Solution Overview
Problem
Existing drag gas nozzles for welding fail to achieve optimal and uniform distribution of protective gas over the welding area while maintaining low gas consumption, often leading to contamination and increased effort in maintaining complex designs.
Innovation Solution
The drag gas nozzle features gas channels with a height at least six times the hydraulic diameter, combined with elements for even flow distribution and a cascading gas distribution system, ensuring laminarization of the gas flow and reduced consumption, allowing for optimal protection of the welding area without the need for additional shielding devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If shielding gas flows through relatively short gas channels, then gas consumption is minimized, but turbulence occurs preventing optimal and even distribution of shielding gas over the welding area
Solution Approach 1:
The gas channels transition from a two-dimensional planar structure to a three-dimensional configuration by introducing a vertical component. The channels extend upward from the base plate at an angle, creating a volumetric flow path that increases the effective length and surface area for gas distribution without significantly increasing the horizontal footprint, thus maintaining low gas consumption while achieving better distribution uniformity
Solution Approach 2:
Different regions of the gas distribution system are given different channel orientations and lengths. The gas channels are arranged with varying angles and positions to create localized flow optimization, ensuring that each region of the welding area receives appropriate gas flow distribution while maintaining overall system efficiency
2Manufacturing precision
If shielding gas flows through long gas channels to achieve laminar flow and uniform distribution, then shielding gas distribution is optimized, but shielding gas consumption increases
Solution Approach 1:
The gas channels utilize vertical space by extending upward at angles from the base plate, effectively increasing the flow path length within a compact horizontal envelope. This three-dimensional arrangement provides sufficient channel length for flow development and uniform distribution without proportionally increasing gas consumption, as the vertical extension does not require additional gas volume in the same way horizontal extension would
3Ease of operation
If porous materials are used for gas distribution, then shielding gas flow is achieved, but soot and weld spatter clog the porous materials preventing their use
Solution Approach 1:
The vulnerable porous distribution layer is extracted and replaced with open, large-bore gas channels that are inherently resistant to clogging. The design removes the problematic porous material entirely and substitutes it with a channel structure that allows soot and spatter to pass through without blocking gas flow, thereby extracting the contamination vulnerability from the system
Solution Approach 2:
While avoiding porous materials in the gas distribution channels, the invention utilizes a perforated base plate with holes that provide gas distribution without the clogging issues of porous structures. The discrete holes maintain gas flow capability while being resistant to contamination from soot and weld spatter
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
This design achieves a uniform and efficient protective gas flow, reducing the risk of air ingress and oxidation, enabling high-quality welds without the need for gas chambers, thus enhancing flexibility and reducing manufacturing costs.
Implementation Method 1
optimal flow and shielding gas distribution are achieved, and laminarization of the shielding gas flow within the gas channels is achieved
Data Source
Figure 1
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AI summary
The invention relates to a trailing gas nozzle (1) for supplying a welding area (S) with a shielding gas (G), comprising a housing (2), a device (3) for attachment to a welding torch (B), an inlet (4) for the shielding gas (G), at least one gas distribution chamber (5), and a plurality of parallel gas channels (6) with openings (7) through which the shielding gas (G) flows onto the welding area (B). To create such a trailing gas nozzle (1), which provides optimal protection for the welding area (S) and is as easy to manufacture as possible, each gas channel (6) has a height (hK) that corresponds to a multiple of the hydraulic diameter (dh) of the gas channel (6).