Two-Piece Welding Nozzle Assembly with Tapered Edison Threads
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Solution Overview
Problem
Existing arc welding guns, such as MIG and GMAW welding guns, face issues with wear due to high temperature operation, particularly in the contact tip and gas diffuser, leading to air intrusion and reduced shielding gas efficiency.
Innovation Solution
A nozzle assembly with a base and nose design featuring tapered Edison threads or shell threads for secure engagement, providing an air seal and tortuous path to prevent air intrusion, while allowing for interchangeable noses to optimize gas direction and reduce thermal seizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact tip and gas diffuser are constantly subjected to high heat operation, then welding function is maintained, but wear occurs leading to air intrusion and reduced shielding gas efficiency
Solution Approach 1:
The nozzle assembly is divided into two separate pieces: a base that remains attached to the conductor tube and an interchangeable nose that can be removed and replaced. This segmentation allows the nose to be easily replaced when worn, preventing air intrusion without replacing the entire assembly, thus maintaining reliability while addressing wear-related air intrusion issues.
Solution Approach 2:
The threaded connection between the base and nose creates a tortuous path that changes the physical configuration of the gas flow path. This parameter change in the flow path geometry prevents air intrusion by creating a more complex sealing interface that resists air leakage while maintaining shielding gas effectiveness.
2Adaptability or versatility
If interchangeable noses with different configurations are used to optimize gas direction, then adaptability to specific welding operations is improved, but device complexity increases
Solution Approach 1:
By separating the nozzle into a base and interchangeable nose sections with standardized threaded connections, the design enables easy swapping of different nose configurations for different welding applications. This segmentation provides adaptability without significantly increasing overall device complexity, as the modular design follows a simple repeatable pattern.
Solution Approach 2:
The standardized threaded connection design allows a single base to accommodate multiple nose configurations, creating a universal interface. This multi-functionality approach enables adaptability to various welding operations through nose selection rather than requiring multiple complete nozzle assemblies, thereby managing device complexity while maintaining versatility.
3Object-affected harmful factors
If tapered Edison threads or shell threads are used to secure the nozzle assembly, then air seal and tortuous path are provided to reduce air intrusion, but manufacturing precision requirements increase
Solution Approach 1:
The use of tapered Edison threads or shell threads changes the geometric parameters of the threaded connection to create a self-sealing effect. The tapered geometry and specific thread profile create a tortuous path that inherently resists air intrusion while accommodating reasonable manufacturing tolerances, balancing air seal performance with manufacturability.
Data Source
AI summary
A nozzle assembly for a welding torch and a welding torch including said nozzle assembly is provided. The nozzle assembly generally comprises a base defining a distal threaded portion for securing the nozzle assembly to a distal end portion of a conductor tube of the welding torch, the base defining a distal threaded portion and a nose defining a mating threaded portion adapted to engage the distal threaded portion of the base, thereby removably securing the nose to the base. The distal threaded portion may comprise tapered Edison threads or a shell thread design.