Welding Torch Nozzle Assembly for Spatter Deflection and Cleaning

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Solution Overview

Problem

Conventional welding torches face issues such as inadequate spatter resistance, difficulty in accessing affected components, nozzle durability problems, and usability challenges, especially for low-skilled operators, along with susceptibility to burn backs.

Innovation Solution

A nozzle design for welding torches featuring a spatter deflecting portion and a single-piece construction that includes a gas diffuser assembly with engagement features, positioned gas holes on the edges of a hexagonal hub for easier cleaning, and the elimination of a G7 insulator for improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a conventional welding torch nozzle is used, then the basic welding function is provided, but spatter resistance is inadequate and components are difficult to access for cleaning

Engineering Contradiction:

Improvespatter resistanceVSAvoidaccess to welding components

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The nozzle is divided into distinct functional portions: a spatter deflecting portion with outwardly sloping surfaces that direct spatter away, and a narrowing neck portion that restricts spatter travel. This segmentation allows each portion to address specific spatter management needs while maintaining cleaning accessibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spatter deflecting portion converts the harmful effect of spatter by using outwardly sloping surfaces to actively redirect spatter away from critical areas. The narrowing neck portion uses the spatter's own momentum against it, creating a bottleneck that prevents spatter from reaching gas ports while still allowing gas flow.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Adaptability or versatility

If multiple parts are used in the nozzle assembly, then assembly flexibility is provided, but nozzle durability is reduced

Engineering Contradiction:

Improveassembly flexibilityVSAvoidnozzle durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The nozzle is constructed as a single-piece component that integrates the spatter deflecting portion, narrowing neck portion, and gas port structure into one durable unit. This eliminates joints and connections that could fail, while engagement features on the single piece allow it to work in conjunction with the gas diffuser assembly for maintained flexibility.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If gas holes are positioned on flat surfaces, then manufacturing is simplified, but cleaning accessibility is reduced

Engineering Contradiction:

Improvegas hole positioningVSAvoidcleaning accessibility

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The gas diffuser assembly uses a hexagonal hub configuration where gas ports are positioned on the edges rather than on flat faces. This asymmetric positioning on edges creates natural access points for cleaning tools while maintaining manufacturing feasibility through standard hexagonal forming processes.

Inventive Principle:

Principle #4Asymmetry

4Reliability

If a G7 insulator is included in the assembly, then electrical insulation is provided, but device complexity and potential failure points increase

Engineering Contradiction:

Improveelectrical insulationVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical insulation function is integrated into the gas diffuser assembly itself rather than requiring a separate G7 insulator component. The gas diffuser assembly is designed to provide both gas distribution and electrical insulation functions, reducing the total part count while maintaining necessary insulation properties.

Inventive Principle:

Principle #5Merging (Combining)

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

The nozzle design significantly reduces spatter reaching critical areas, enhances cleaning ease, and improves durability by eliminating the need for multiple parts, while maintaining or exceeding the performance of conventional heavy-duty nozzles.

Implementation Method 1

The spatter deflecting portion is configured to block or deflect weld spatter that enters the front opening from traveling past the narrowing neck portion

Methodology Applied

Scientific EffectDeflection:

Implementation Method 2

an internal surface surrounding the internal passage... a gas diffuser assembly with engagement features, positioned gas holes

Methodology Applied

Scientific EffectGas distribution:

Data Source

PatentEP3562614B1Nozzle for a welding torch, and welding torch with such nozzle

Publication Date: 2021.03.03 ILLINOIS TOOL WORKS INC

Figure 1
Figure 2
Figure 3a~3b

AI summary

A nozzle assembly for a welding torch is disclosed. The nozzle assembly comprises a nozzle, a contact tip, and a gas diffuser assembly. The gas diffuser assembly comprises a gas diffuser, coupled to an insulator. The gas diffuser is also coupled to a gooseneck and the contact tip. The nozzle is coupled to the gas diffuser assembly, such that the contact tip is retained within the nozzle. The nozzle and gas diffuser assembly further include complementary engagement features to couple the nozzle to the gas diffuser assembly. The nozzle also includes a spatter deflector configured to deflect or block spatter from obstructing gas holes of the gas diffuser assembly.