Welding Torch Nozzle Structure for Longer Shield Gas Laminar Flow
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Solution Overview
Problem
The existing welding torch designs suffer from a shortened laminar flow length of the shield gas stream, leading to vortex generation and compromised welding quality due to the configuration of the gas path within the nozzle.
Innovation Solution
A welding torch design featuring a cylindrical tip body, an orifice member with a first ring-like space, and a nozzle with a second ring-like space, where the second space is sealed by a large radius part and a tapered flow straightening wall, guiding the shield gas to extend its laminar flow length and reduce vortex formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the space inside the nozzle extends toward the torch base side, then the nozzle structure is simplified, but a drift including a vortex is generated in the gas stream which shortens the laminar flow length
Solution Approach 1:
The gas flow path is segmented into distinct zones: a first ring-like space for gas introduction, a second ring-like space for laminar flow development, and a sealed region. This segmentation allows the gas stream to maintain laminar flow by preventing premature contact with the torch base side structures, thus extending the laminar flow length while keeping the nozzle structure manageable.
Solution Approach 2:
A sealing part is introduced as an intermediary element to close the second ring-like space. This sealing part acts as a mediator that prevents gas stream interaction with the torch base side, eliminating vortex generation while maintaining a relatively simple nozzle structure. The sealing part bridges the gap between structural simplicity and flow stability requirements.
2Ease of manufacture
If the outlet opening of the second emission hole is arranged away from the sealed end, then the gas flow path is longer, but the laminar flow length is shortened due to vortex generation
Solution Approach 1:
The second emission hole is positioned such that its outlet opening is arranged close to the sealing part that closes the second ring-like space. This preliminary positioning ensures that the gas stream enters the laminar flow zone immediately after emission, maximizing the laminar flow length before the gas reaches the welding target. The sealing part is pre-positioned to prevent vortex formation in advance.
3Ease of manufacture
If the space inside the nozzle is open toward the torch base side, then the assembly is easier, but the gas stream generates drift and vortex which deteriorates welding quality
Solution Approach 1:
The harmful vortex-generating region is extracted and isolated by introducing a sealing part that closes the second ring-like space. This extraction removes the source of drift and vortex from the gas flow path, preventing welding quality deterioration. The sealing part can be integrated into the nozzle assembly maintaining ease of manufacture while eliminating the harmful effects.
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 extended laminar flow length of the shield gas stream ensures a sufficient shield width at the welding target point, improving the overall welding quality by minimizing vortex-induced drift and enhancing gas efficiency.
Implementation Method 1
a tapered flow straightening wall with a radius decreasing as it extends toward the other side in the axis line direction is formed
Implementation Method 2
the second ring-like space is substantially closed by a sealing part on another side in the axis line direction
Data Source
AI summary
A welding torch includes: a cylindrical tip body extending in an axis line direction; an orifice member arranged on a radially outer side of the tip body, between which and the tip body a first ring-like space is formed; a cylindrical nozzle arranged on a radially outer side of the orifice member with an interposition of a second ring-like space and having an edge on one side in the axis line direction. The tip body has a first emission hole via which an inner space of the tip body communicates with the first ring-like space, and the orifice member has a second emission hole via which the first ring-like space communicates with the second ring-like space. The second ring-like space is substantially closed by a sealing part on another side in the axis line direction, and an outlet opening of the second emission hole is arranged close the sealing part.