Welding Torch Tubular Joint with Cold-Formed Interlocking
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Solution Overview
Problem
Current joining methods for welding torch components, such as brazing, weaken materials, increase costs, and result in unwanted warping and surface quality issues, while alternative methods lack mechanical and electrical conductivity.
Innovation Solution
A joined connection and method using interlocking surface structures with indentations and elevations on tubular segments that deform plastically to create a strong, fluid-tight, and conductive bond without thermal joining, utilizing elastic deformation and support rings for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to join welding torch components, then high mechanical strength and permanent gas tightness are achieved, but the material near the brazing site is weakened and unwanted warping occurs
Solution Approach 1:
The patent replaces the thermal brazing process with a mechanical cold-forming joining process. Indentations are pressed into the surface of one tubular component, and the other component is forced into these indentations, creating an interlocking mechanical connection without thermal input. This substitution eliminates heat-affected zone damage while maintaining joint strength through geometric interlocking and material deformation.
Solution Approach 2:
The joining process is segmented into distinct steps: first creating indentations on one component surface, then forcing the second component into these pre-formed indentations. This segmentation allows controlled material deformation and interlocking formation, distributing the joining action across multiple stages rather than a single thermal process.
2Stability of the object's composition
If low-melting solder is used to reduce heat input at the brazing site, then material weakening is reduced, but costs increase and pickling becomes necessary
Solution Approach 1:
The patent completely eliminates the soldering/brazing process and its associated materials (solder, flux, pickling compounds) by using a pure mechanical cold-forming joining method. This substitution removes all chemical processing steps while maintaining joint integrity through mechanical interlocking, thereby reducing both material costs and environmental impact.
3Reliability
If brazing is used to achieve high electrical and thermal conductivity, then good conductivity is obtained, but surface quality deteriorates and solder penetrates into interior spaces
Solution Approach 1:
By replacing thermal brazing with mechanical cold-forming, the patent prevents solder penetration into interior spaces and avoids surface discoloration. The mechanical pressing process maintains precise surface geometry while creating the joining connection through indentation interlocking, preserving both aesthetic and functional surface quality.
4Ease of manufacture
If pressing/embossing methods are used to join tubular segments, then manufacturing is simplified, but the required structural space is increased and material flowing occurs
Solution Approach 1:
The patent applies local quality by creating indentations only at the specific joining interface area rather than deforming the entire component. This localized surface modification achieves the necessary mechanical interlocking without requiring extensive material deformation or large structural changes, thereby minimizing the volume increase while maintaining manufacturing simplicity.
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 solution achieves mechanical stability and conductivity comparable to brazed connections with improved resistance to twisting and bending, while being easier to produce and maintaining fluid-tightness.
Implementation Method 1
In the joined state, the indentations are at least partly filled with material of the second tubular segment by virtue of a plastic deformation of the second tubular segment occurring during the joining process
Implementation Method 2
the resulting interlocking is formed in at least two directions of the joining surfaces bordering one another
Data Source
AI summary
The present invention concerns a joined connection and a joining method for welding torch components with a first metallic tubular segment and a second metallic tubular segment, which are joined to each other by plastic deformation via an interlocking connection. The problem which the invention proposes to solve is to indicate a joined connection as well as a joining method in which two metallic welding torch components can be joined without the use of thermal joining methods, yet with comparable quality. The problem is solved in that the interlocking is formed in at least two directions of the joining surface bordering one another.