Helical Welding Torch Liner for Debris Ejection and Anti-Clogging

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Solution Overview

Problem

Conventional welding torches experience clogging due to wear debris accumulation in the inner tube, requiring frequent disassembly for cleaning, as the shielding gas supplied from the torch holder can flow back to the feed unit and cause debris to accumulate.

Innovation Solution

A welding torch design featuring a helically wound inner tube with gaps between adjacent wires to allow shielding gas to flow through, preventing reverse gas flow and ejecting wear debris out through the nozzle, along with a sealing mechanism to prevent gas reversal and a guide member to manage the welding wire.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a conventional welding torch uses a solid inner tube to protect the welding wire passage, then the structural integrity is improved, but wear debris accumulates and clogs the inner tube requiring frequent cleaning

Engineering Contradiction:

Improvestructural integrityVSAvoidcontinuous operation without clogging

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The inner tube is constructed with a porous structure that allows wear debris to pass through while maintaining structural integrity. This porous design enables the tube to filter and eject debris through its walls, preventing clogging and ensuring continuous operation without frequent cleaning interruptions.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The inner tube is divided into multiple sections with different characteristics - a upstream section with larger diameter to reduce contact friction, and a downstream section with porous structure to enable debris ejection. This segmentation allows each section to perform its specific function optimally while working together to prevent clogging.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the shielding gas flows back to the feed unit, then the gas supply efficiency is improved, but wear debris accumulates in the inner tube forming clogs

Engineering Contradiction:

Improvegas supply efficiencyVSAvoiddebris-free operation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A sealing member is introduced as an intermediary component between the inner tube and conduit to control gas flow direction. This sealing member prevents reverse flow of shielding gas to the feed unit while allowing the gas to effectively supply the welding area, thus maintaining productivity while preventing debris accumulation caused by reverse flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The harmful reverse flow of gas is extracted and eliminated from the system by positioning the sealing member to block the reverse path. This extraction of the problematic gas flow pattern prevents wear debris from being carried back to the feed unit and accumulating in the inner tube.

Inventive Principle:

Principle #2Taking out (Extraction)

3Force

If the inner tube has tight winding to reduce gaps, then the contact friction with welding wire is reduced, but wear debris cannot be ejected effectively

Engineering Contradiction:

Improvecontact frictionVSAvoiddebris ejection capability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The inner tube exhibits local quality variations with different winding densities in different sections. The upstream section has tighter winding to minimize contact friction with the welding wire, while the downstream section has a porous structure with appropriate gap size to enable effective wear debris ejection. This local differentiation allows both low friction and effective debris removal to coexist.

Inventive Principle:

Principle #3Local quality

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

Prevents clogging of the inner tube without the need for frequent disassembly, ensuring a continuous welding operation by effectively ejecting wear debris with the shielding gas, thus maintaining the feeding mechanism's performance.

Implementation Method 1

a gap is defined between the adjacent wires of the inner tube allowing the shield gas to flow therethrough

Methodology Applied

Scientific EffectGas flow through gaps:

Implementation Method 2

a sealing mechanism to prevent a reverse flow of the shield gas to the feed unit

Methodology Applied

Scientific EffectGas flow direction control:

Implementation Method 3

wear debris generated by abrasion of the welding wire sliding in the inner tube

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11745284B2Welding torch

Publication Date: 2023.09.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A welding torch includes an inner tube of a helically wound wire to define a passage for a welding wire, a conduit in which the inner tube is inserted, the conduit having a curved portion, a torch body including a tip portion and a nozzle, a torch holder having a gas supplying member that supplies a shield gas into a space between the inner tube and the conduit, a feed unit provided upstream of the torch holder to feed the welding wire forward to or backward from the inner tube, and a sealing mechanism for preventing a reverse flow of the shield gas to the feed unit. A gap is defined between the adjacent wires of the inner tube allowing the shield gas to flow therethrough, and permitting wear debris generated by abrasion of the welding wire sliding in the inner tube to be ejected out from the nozzle.