TIG Welding Torch

Abstract

A TIG welding torch (10) including a torch body (22), a metallic front section of the torch body (22) for holding a tungsten rod and conducting electricity to the tungsten rod, and a ceramic nozzle (48a,b,c) for surrounding the metallic front section, wherein a heat isolation spacer (36a,b,c) is provided between the metallic front section and the ceramic nozzle (48a,b,c), the nozzle (48a,b,c) bearing against the outside of the heat isolation spacer (36a,b,c), the heat isolation spacer (36a,b,c) being attached, at a point of attachment, to the metallic front section at a rear end of the metallic front section and a rear end of the heat isolation spacer (36a,b,c), and the heat isolation spacer (36a,b,c) extending forwards of the point of attachment, spaced from the metallic front section to provide a thermal break between the nozzle (48a,b,c) and the metallic front section, and the ceramic nozzle (48a,b,c) being in contact with the heat isolation spacer (36a,b,c) forward of the point of attachment when the ceramic nozzle (48a,b,c) is fitted.

Claims

1. A TIG welding torch including a torch body, a metallic front section of the torch body for holding a tungsten rod and conducting electricity to the tungsten rod, and a ceramic nozzle for surrounding the metallic front section, wherein a heat isolation spacer is provided between the metallic front section and the ceramic nozzle, the nozzle bearing against the outside of the heat isolation spacer, the heat isolation spacer being attached, at a point of attachment, to the metallic front section at a rear end of the metallic front section and a rear end of the heat isolation spacer, and the heat isolation spacer extending forwards of the point of attachment, spaced from the metallic front section to provide a thermal break between the nozzle and the metallic front section, and the ceramic nozzle being in contact with the heat isolation spacer forward of the point of attachment when the ceramic nozzle is fitted.

2. A TIG welding torch as claimed in claim 1, in which the metallic front section includes a cooling passage or thermal break in the form of a cavity, the cooling passage extending at least to a longitudinal point corresponding to the point of attachment between the heat isolation spacer and the metallic front section.

3. A TIG welding torch as claimed in claim 1, in which the heat isolation spacer is made from a material having lower thermal conductivity than that of the metallic front section of the welding torch.

4. A TIG welding torch as claimed in claim 3, in which the heat isolation spacer is made from stainless steel and the metallic front section of the welding torch is made from brass and/or copper.

5. A TIG welding torch as claimed in claim 1, in which the heat isolation spacer is tapered inwardly towards the front of the torch.

6. A TIG welding torch as claimed in claim 5, in which the ceramic nozzle has a tapered internal profile.

7. A TIG welding torch as claimed in claim 1, in which the heat isolation spacer is attached to the metallic front section of the torch by means of a screw thread.

8. A TIG welding torch as claimed in claim 7, in which at least two thirds of the length of the heat isolation spacer extends in front of the screw thread and does not contact the metallic front section of the torch.

9. A TIG welding torch as claimed in claim 1, in which longitudinal slots are provided part way along the heat isolation spacer, extending from the front of the heat isolation spacer, the slots defining leaf springs between the slots.

10. A TIG welding torch including a torch body, a metallic front section of the torch body for holding a tungsten rod and conducting electricity to the tungsten rod, and a ceramic nozzle for surrounding the metallic front section, wherein a heat isolation spacer is provided between the metallic front section and the ceramic nozzle, the heat isolation spacer being attached, at a point of attachment, to the metallic front section at a rear end of the metallic front section and a rear end of the heat isolation spacer, and the heat isolation spacer extending forwards of the point of attachment, spaced from the metallic front section to provide a thermal break between the nozzle and the metallic front section, the heat isolation spacer being tapered inwardly towards the front of the torch and the heat isolation spacer having longitudinal slots extending from the front of the heat isolation spacer and being provided part way along the heat isolation spacer, the slots defining leaf springs between the slots, and the ceramic nozzle being in contact with the heat isolation spacer forward of the point of attachment when the ceramic nozzle is fitted, an inner surface of the nozzle bearing against an outer surface of the heat isolation spacer, and the leaf springs acting outwardly against the inner surface of the nozzle to grip the nozzle and retain the nozzle on the heat isolation spacer.

11. A TIG welding torch as claimed in claim 10, in which the heat isolation spacer is made from stainless steel.

12. A TIG welding torch including a torch body and a back cap, the back cap is elongate and hollow with an open end, the back cap being attachable to the torch body by a screw thread, the torch body being overmoulded with a resilient material, the overmoulding extending behind a brass body of the torch body and the back cap including an exterior tapered front section at the open end for interfacing with and sealing against the resilient overmoulding of the torch body.

13. A TIG welding torch as claimed in claim 12, in which the overmouldling is a silicone-based material.

14. A TIG welding torch as claimed in claim 12, in which the back cap is attached to the torch body by screw threading the back cap to a collet inserted through the torch body from the front of the torch body.

Description

DESCRIPTION OF THE DRAWINGS

[0034] For a better understanding of the invention, and to show more clearly how it may be carried into effect, preferred embodiments will now be described with reference to the accompanying drawings, in which:

[0035] FIG. 1 is a perspective view of a liquid-cooled TIG welding torch according to the invention, including three different options for the collet, heat isolation spacer, nozzle and band;

[0036] FIG. 2 is a perspective view of the back cap of the TIG welding torch of FIG. 1;

[0037] FIG. 3 is a perspective view of two different options for the heat isolation spacer of the TIG welding torch of FIG. 1;

[0038] FIG. 4 is a perspective view of a collet which is part of the TIG welding torch of FIG. 1;

[0039] FIG. 5 is a perspective view of a collet with an integrated gas lens which is an alternative option for the collet of the TIG welding torch of FIG. 1;

[0040] FIG. 6 is a cutaway view of the TIG welding torch of FIG. 1, showing liquid and gas flow channels; and

[0041] FIG. 7 is a cutaway view of a gas-cooled TIG welding torch according to the invention, fitted with the integrated gas lens collet of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] Referring firstly to FIG. 1, a liquid-cooled TIG welding torch is indicated generally at 10. The torch is shown in a disassembled state, and three different options of the collet, nozzle, heat isolation spacer and band are shown.

[0043] The torch includes a torch body 12. The torch body includes an interface section 14 for attaching the torch to a welding machine. The interface section 14 includes a cooling liquid inlet 16 and a cooling liquid outlet 18, and a shield gas inlet 20. The liquid inlet and outlet 16,18 and the gas inlet 20 are all copper tubes. The copper tubes are brazed to a brass body 22. The copper tubes and the brass body together form a good electrical conductor, and so can also be used to electrically connect the welding torch to the welding machine, so that voltage can be supplied to the torch to strike an arc and make a weld.

[0044] The brass body extends along the neck section 24 and head 26 of the torch 10. The brass body 22 is overmoulded with an insulating material, for example silicone rubber. The neck section 24 includes a location formation 28 for a moulded handle in the form of an insulated casing (not shown in the drawings). The insulating casing may be rigid plastic and may be, for example, snapped or screwed together over the bottom part of the neck section of the overmoulded brass body 22. The insulating casing 28 extends from the neck section 24 to form a handle on the welding torch.

[0045] The brass body 22 in the head section 26 is hollow, i.e. an aperture passes all the way through the brass body 22 along the line indicated A.

[0046] The frontmost part 30 of the insulated section of the head 26 of the torch includes a rib 32. The backmost section of the uninsulated (exposed brass) part of the head 26 of the torch includes an external screw thread 34.

[0047] To assemble the torch, one of the heat isolation spacers 36a, 36b, 36c is screwed onto the screw thread 34 on the front of the brass body 22. One of the collets 38a, 38b, 38c is then passed through the centre of the heat isolation spacer 36a,b,c, and through the aperture in the head section 26 of the brass body 22. Each of the collets 38a,b,c includes an external screw thread 40a,b,c and this screw thread 40a,b,c corresponds with an internal screw thread 44 on the front of the back cap 42. Therefore, the collet 38a,b,c, torch body 12 and back cap 42 can all be held together by screwing the internal thread 44 of the back cap 42 onto the external thread 40a,b,c of the collet 38a,b,c.

[0048] When the collet is fitted, a band 46a,b,c can be stretched around the frontmost insulated section 30 of the torch body 12. A rib 32 on the torch body assists with retaining the band 46a,b,c onto the torch body 12, and preferably the band 46a,b,c also has one or more internal ribs. A nozzle 48a,b,c can then be fitted over the heat isolation spacer 36a,b,c. The nozzle 48a,b,c will be centred and held by the heat isolation spacer 36a,b,c. The front part of the band 46a,b,c is stretched over a rear section of the nozzle 48a,b,c. At least one rib (not visible in the drawing) is provided on the inside of the band 46a,b,c which assists with gripping of the band around the back part of the ceramic nozzle 48a,b,c. In some other embodiments, rib(s) may also be provided around the outside of the back of the nozzle.

[0049] Nozzles can be of a variety of shapes, sizes, diameters and lengths to suit specific welding requirements.

[0050] FIG. 2 shows the back cap 42 in more detail. The back cap is elongate and hollow, so that it can retain the back part of a tungsten rod. It is open at the end facing the torch body 12 in use (the bottom end in FIG. 2). The back cap is made from plastics, and has a brass threaded insert 50 at the open end. The exterior of the open end is tapered. The taper angle is preferably 30 degrees.

[0051] The tapered front section of the back cap 42 forms a seal against the silicone overmoulding of the torch body 12, when the torch is assembled. The silicone overmoulding of the torch body 12 for this reason extends substantially behind the brass body 22 of the head 26 of the torch. Back caps can be supplied in a variety of lengths and are easily interchangeable on the torch to suit different requirements, for example restricted access to the weld site may require a shorter back cap.

[0052] FIG. 3 shows the heat isolation spacers 36a,b. Each of the heat isolation spacers is made from stainless steel, and each is substantially in the form of a tapered elongate shell which is wide towards the rear (towards the top of the FIG. 3 drawings) and narrower towards the front. Longitudinal slots 52 extend from the front of each heat isolation spacer, along for example two thirds of the length of the heat isolation spacer. The slots are equally spaced around the circumference of the heat isolation spacer, for example five slots may be provided spaced by 72 degrees. The stainless steel leaves defined by the slots form leaf springs, and so when the nozzle 48a,b,c is pushed onto the front of the heat isolation spacer 36a,b,c the leaves will deform inwardly, but push outwardly onto the inside surface of the nozzle 48,a,b,c, holding the nozzle in place on the heat isolation spacer. Each of the heat isolation spacers 36a,b includes an internal screw thread 54, near the rear end of the heat isolation spacer. The internal screw thread 54 corresponds with the screw thread (34, FIG. 1) on the brass body 22 of the head 26 of the torch, so that the heat isolation spacer may be screwed onto the brass body 22. The heat isolation spacer is designed to provide a thermal break between the nozzle and the body 22, thus preventing heat generated from the welding process from being transmitted to the body 22.

[0053] FIG. 4 shows the collet 38c in more detail. The collet comprises a rear attachment section 56, a central heat sink section 58 and a front grip section 60. The rear attachment section 56 includes the external screw thread 40c which corresponds with the internal screw thread on the threaded insert (50, FIG. 2) of the back cap (42, FIGS. 1,2). Also, a longitudinal slot 62 extends from the rear of the collet 38c, cutting through the screw thread and terminating in front of the screw thread 40c. A rib 64 is provided at the end of the screw thread, and the slot 62 passes also through the rib 64. The rib 64 provides a shoulder to limit how far the collet 38c can be screwed into the back cap (42).

[0054] The slot corresponds to the position of a pin which extends from the inside wall of the hollow brass body of the torch head (26). As the collet 38c is passed through the aperture in the brass body, the pin slides into the slot 62. The pin and slot 62 prevent rotation of the collet 38c with respect to the brass body (22). This ensures that the collet 38c can be tightened onto the back cap (42) simply by holding the torch (for example by its handle) and rotating the back cap (42).

[0055] The heat sink section 58 of the collet 38c includes spines 65, and channels 61 running between the spines 65. In use, shield gas passes through the channels 61 on its way from the gas inlet (20) and out of the front of the nozzle (48c). This assists with cooling the torch.

[0056] The front grip section 60 of the collet 38c is the part which grips the tungsten rod when the collet 38c is closed. A tapered section 66 is provided, which is wider towards the front of the collet 38c and narrower towards the rear. In use, the tapered section 66 passes into the front of the aperture in the brass body (22) of the head (26) of the torch. As the collet 38c is drawn backwards by tightening the screw thread 40c onto the back cap 42, wider and wider parts of the tapered section 66 are drawn into the aperture in the brass body (22) of the head (26). This closes the jaws of the collet 38c to retain the tungsten rod. Preferably, the front opening of the aperture in the brass body (22) is internally tapered to match the taper 66 of the collet 38c. The jaws will therefore move from fully open to fully closed on very slight movement of the collet 38c from an open position where the front edge of the tapered section 66 is just in line with the opening of the body (22) of the head (26), to a closed position where the front edge of the tapered section 66 is recessed within the opening of the body (22) of the head (26) by for example 0.5 mm. In front of the front edge of the tapered section 66, an undercut 68 is provided. The undercut 68, together with longitudinal slots 70 through the tapered section 66, provide gas flow channels to allow shield gas to flow from the channels 61 of the heat sink section 58, through the front of the collet 38c and out of the nozzle.

[0057] FIGS. 5a and 5b show an alternative collet 38b. The collet 38b again has an attachment section 56 and a heat sink section 58. These parts are substantially identical to those of the collet 38c in FIG. 4. The grip section 60 likewise includes a tapered section 66, an undercut 68 and longitudinal slots 70. However, this alternative collet 38b is provided with an integrated gas lens 72. The gas lens 72 is of a known typea series of meshes provided in the path of the shield gas serves to direct the shield gas, ensuring more uniform flow and better welding performance. The gas lens 72 is integrated into the collet. This is done by providing circumferential slots around the jaws of the collet. Internal rings on the gas lens assembly 72 are retained in the circumferential slots. This allows the gas lens to be fitted around the jaws of the collet, which means there is no increase in the length of the torch when fitted with a gas lens. This allows the advantages of the gas lens to be realised without making the torch long and cumbersome.

[0058] FIG. 6 shows the welding torch of FIG. 1, when fully assembled. Parts of the torch are cut away so that gas and liquid flows can be seen.

[0059] The band 46c is seen fitted in FIG. 6, providing a gas-tight seal between the nozzle and the torch body. The band 46c is shown in cross-section, and internal ribs on the band are visible, both where the band 46c contacts the torch body and where the band contacts the nozzle 48c.

[0060] At the back of the torch body, a pin 63 is visible. The pin 63 corresponds with the slot (62) in the collet 38c, to prevent the collet 38c from rotating with respect to the torch body when it is fully inserted into the aperture in the torch body. Also clear from FIG. 6 is the extent of the silicone overmoulding behind the brass body 22 of the torch head 26. The silicone overmoulding extends behind the brass body 22 by almost the extent of the tapered section of the back cap 42. With the back cap 42 fully tightened onto the collet 38c, the tapered section of the back cap 42 forms a gas-tight seal with the silicone overmoulding of the torch head 26, preventing any leaking of shield gas out of the back of the torch.

[0061] The front section of the brass body 22 of the torch is also shown in cross-section, and the tapered entrance which corresponds to the tapered section 66 of the collet 38c is visible.

[0062] The flow of inert shield gas through the welding torch 10 is indicated by arrows. From the end of the inlet tube 20 at the top of the neck (to the left of FIG. 6), shield gas flows in the channels (61) of the collet 38c, between the collet 38c and the inside wall of the brass body of the torch head 26. The gas then flows through the slots (70) in the jaws of the collet 38c, and then out of the small gap between the collet 38c and the front edge of the brass body 22, at the very front of the undercut (68) in the collet 38c. The gas is then directed towards the workpiece by the nozzle 48c.

[0063] The brass body 22 of the head 26 of the torch 10 has a hollow wall. This forms a liquid-filled jacket which allows cooling liquid to pass from liquid inlet 16, into the hollow wall of the brass body, and then out of the liquid outlet 18. The liquid jacket is indicated at 74.

[0064] The heat isolation spacer 36c is shown installed on the torch with the thread 54 screwed onto the brass torch body 22. It is apparent from the cross section in FIG. 6 that the heat isolation spacer 36 is only in contact with the brass body at the thread 54, and just to the rear of the thread. The parts of the heat isolation spacer 36c which are forward of the thread 54 are spaced from the brass body 22. This reduces heat transfer from the nozzle into the brass body. It will also be noted that the small part of the brass body which is in contact with the heat isolation spacer is substantially centrally disposed relative to the hollow wall section, which is cooled by liquid. These features increase the time for which welding can be carried out before the handle of the torch becomes hot.

[0065] FIG. 7 shows the gas-cooled version of the torch of FIG. 6. Again, arrows show the flow of gas through the torch. The gas flow is identical to that in the torch of FIG. 6, passing through the channels in the collet 38b, and then out of the front, directed by the nozzle. The gas-lens version of the collet 38b is fitted in FIG. 7, but equally the collet 38c without the gas lens could be fitted to the gas-cooled torch 10.

[0066] The construction of the brass body 22 of the torch 10 is again almost identical to that of torch 10. The brass body 22 still has a hollow wall, although no liquid flows within the cavity. Instead, the hollow cavity 75 in the brass body 22 forms a thermal break, insulating the outside of the brass body from the inside. This reduces heat transfer from the nozzle 48b, which is closest to the hot workpiece, into the brass body 22 and then to the handle of the torch 10. Again, the heat isolation spacer 36b is only in contact with the brass body 22 over a very small area, and the area of contact is substantially central on the extent of the hollow thermal break 75.

[0067] The torches 10, 10 retain the nozzle 48a,b,c using the heat isolation spacer to grip the nozzle from the inside. The nozzles 48a,b,c therefore do not require manufacture with a screw thread, which increases possible manufacturing tolerances, reduces cost, and improves durability. The collet 38a,b,c will also last longer than in similar known torches, because it is not subject to twisting forces when tightened. The twisting from rotation of the back cap 42 is resisted very close to the back cap 42 longitudinally, by the pin 63 in the slot 62.

[0068] The gas seal at the back of the torch 10, 10 is also more reliable and longer lasting than in known designs. The tapered front section of the back cap 42, which seals against the silicone overmoulding behind the back of the brass body 22, provides a high-quality seal.

[0069] Finally, the torch 10, 10 has excellent thermal performance compared with known designs. The nozzle is joined to the body of the torch via a heat isolation spacer 36a,b,c. The heat isolation spacer is made from stainless steel which has lower thermal conductivity than brass or copper, and the area of contact between the heat isolation spacer and the brass body is very small. Furthermore, where the heat isolation spacer does contact the brass body, there is either a thermal break or liquid cooling channel, limiting the heat that is transferred into the handle of the torch.

[0070] The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.