Shielding gas weld cone and method

A device for distributing gas near a weld location includes a cap, a funnel, an inlet, and an aperture. The cap includes a sidewall and an annular lip, and defines a reservoir between the sidewall and the annular lip. The annular lip includes a proximal-most edge. The cap defines an opening, and defines a longitudinal axis. The funnel is disposed adjacent a distal end of the cap. The inlet is disposed in mechanical cooperation with the cap. The aperture is disposed through the sidewall of the cap and is in fluid communication with the inlet. The aperture is disposed distally of the proximal-most edge of the annular lip. Gas is configured to flow through the inlet, through the aperture and into the reservoir. The reservoir is configured to allow the gas to uniformly overflow the proximal-most edge of the annular lip and flow distally through the opening defined by the cap.

BACKGROUND

Technical Field

The present disclosure relates to a device for use during a welding process, and, more particularly, to a cone for use during welding using shielding gas and a related method.

Background of Related Art

When manufacturing and assembling surgical instruments, it is often desired to weld two or more components together. Further, shielding gas (e.g., argon gas) may be used during the welding process for various instruments, including surgical instruments. Shielding gases, such as argon, are inert gases that are typically used in a laser welding process to help prevent oxidization of the weld and to shield a laser arc from outside contaminants and gases, which may react with the weld causing aesthetic disparities, excessive slag, and weld inconsistency. Directing the flow of shielding gas to the location of the weld is often challenging because shielding gas is heavier than air, and thus gathers in flow streams instead of dispersing with the air for a more uniform application.

The ability to uniformly pour shielding gas over the location of the weld is desirable to create a shield from outside contaminates.

SUMMARY

The present disclosure relates to a device configured for distributing gas near a weld location. The device including a cap, a funnel, an inlet, and an aperture. The cap includes a sidewall and an annular lip, and defines a reservoir between the sidewall and the annular lip. The annular lip includes a proximal-most edge. The cap defines an opening, and has a longitudinal axis extending through a radial center of the opening from a proximal end of the opening to a distal end of the opening. The funnel is disposed adjacent a distal end of the cap. The inlet is disposed in mechanical cooperation with the cap. The aperture is disposed through the sidewall of the cap and is in fluid communication with the inlet. The aperture is disposed distally of the proximal-most edge of the annular lip. Gas is configured to flow through the inlet, through the aperture and into the reservoir. The reservoir is configured to allow the gas to uniformly overflow the proximal-most edge of the annular lip and flow distally through the opening defined by the cap.

In aspects of the present disclosure, the funnel is selectively engageable with the cap.

In other aspects, the funnel is configured to selectively engage the cap with a plurality of magnets.

In still other aspects, the device includes a first plurality of magnets disposed on a distal end of the cap, and a second plurality of magnets disposed on a proximal end of the funnel.

In yet other aspects, a distal end of the cap is disposed at a non-perpendicular angle with respect to the longitudinal axis, and a proximal end of the funnel is disposed at a non-perpendicular angle with respect to the longitudinal axis. In disclosed aspects, the device includes a first plurality of magnets disposed on the distal end of the cap, and a second plurality of magnets disposed on the proximal end of the funnel.

The present disclosure also related to a method of manufacturing an instrument. The method includes positioning a weld cone adjacent a weld site, the weld cone including a sidewall and an annular lip, and defining a reservoir between the sidewall and the annular lip, ensuring a proximal-most edge of the annular lip is level, engaging a supply of shielding gas with the weld cone, and filling the reservoir with shielding gas such that the shielding gas flows over the proximal-most edge of the annular lip, which thereby creates a uniform curtain of shielding gas adjacent the weld site.

In aspects of the present disclosure, the method also includes inserting a portion of a welding device within an opening of the weld cone, and also includes using the welding device to emit a laser arc toward the weld site, such that the laser arc is disposed within the curtain of shielding gas.

In other aspects, the method includes selectively engaging and disengaging a funnel of the weld cone with a cap of the weld cone.

DETAILED DESCRIPTION

Embodiments of the presently disclosed shielding gas weld cone are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

With initial reference toFIG. 1, an embodiment of an shielding gas weld cone in accordance with the present disclosure is shown generally identified by reference character100. Although shielding gas weld cone100is shown configured for use in connection with the assembly and manufacture of surgical instruments, the present disclosure is equally applicable for utilizing the shielding gas weld cone100for the assembly and/or manufacture of other devices where the use of welding may be desired.

With initial reference toFIGS. 1 and 2, shielding gas weld cone100is configured for use in a manufacturing or welding environment10. Such an environment10is often suitable for the manufacture and assembly of various devices (e.g., a surgical instrument20, or portions thereof). During many assembly and manufacturing methods, using shielding gas (e.g., argon) during the welding process can help prevent oxidization of the weld and shield a laser arc from outside contaminants and gases, thus resulting in a more aesthetic weld having reduced slag and greater weld consistency, for example. However, directing the flow of shielding gas to the location of the weld is often challenging because shielding gas is heavier than air, and thus gathers in flow streams instead of dispersing with the air for a more uniform application.

Shielding gas weld cone100of the present disclosure enables a uniform shield or curtain of shielding gas “SG” to be directed toward or poured over the location of the weld, as shown inFIGS. 1 and 2.

With reference toFIGS. 3-5, shielding gas weld cone100includes a ring-like cap120, a pair of inlets140a,140b, and a frusto-conical portion or funnel160. In the illustrated embodiment, inlets140a,140bare each in fluid communication with a separate aperture142extending through a sidewall126of cap120and disposed on opposite sides of cap120. Funnel160is engaged with or depends from cap120. More or fewer inlets140a,140band apertures142may be provided. Shielding gas weld cone100defines a longitudinal axis “A-A,” as shown inFIG. 4.

More particularly, cap120includes a proximal end122, a distal end124, sidewall126, and a lip130. As shown inFIG. 4, an annular channel or reservoir132is defined between lip130and sidewall128of cap120. Additionally, apertures142extend through sidewall126of cap120and are in fluid communication with reservoir132. A proximal-most edge131of lip130is positioned farther proximally than a proximal-most portion of apertures142.

Funnel160extends distally from cap120and is configured to direct shielding gas “SG” toward the weld site. Funnel160may be connected to cap120, integrally formed with cap120, coupled to cap120, affixed to cap120, or selectively attachable to and removable from cap120, for example. In the illustrated embodiment, funnel160selectively engages cap120with a plurality of magnets180(seeFIG. 4). In particular, a first set of magnets180ais disposed at least partially within cap recesses121at distal end124of cap. Additionally, a second set of magnets180bis disposed at least partially within funnel recesses161at a proximal end163of funnel160.

The polarity of magnets180is configured such that first set of magnets180aand second set of magnets180bare attracted to each other. It is envisioned that the polarity of the magnets in first set of magnets180aand the polarity of the magnets in second set of magnets180balternate, such that funnel160and cap120can only engage one another at predefined radial orientations (e.g., only two radial orientations when first set of magnets180aincludes four magnets, and when second set of magnets180bincludes four magnets, as shown inFIG. 5).

With particular reference toFIG. 4, distal end124of cap120is tapered or disposed at a non-perpendicular angle with respect longitudinal axis “A-A.” Additionally, proximal end163of funnel160is tapered or disposed at a non-perpendicular angle with respect longitudinal axis “A-A.” The tapered portions of cap120and funnel160help ensure and maintain proper positioning therebetween during assembly and during use, for instance. That is, the tapered portions help prevent funnel160from sliding laterally (i.e., perpendicular to the longitudinal axis “A-A”) relative to cap120, for example.

Referring back toFIGS. 1 and 2, in use, shielding gas weld cone100is positioned adjacent a desired weld location such that the curtain of shielding gas “SG” will be directed toward the desired weld location via funnel160. Additionally, shielding gas weld cone100is positioned such that proximal-most edge131of lip130of cap120is level (with respect to ground). That is, shielding gas weld cone100is positioned such that longitudinal axis “A-A” is perpendicular to the ground. It is envisioned that shielding gas weld cone100includes a built-in level (e.g., a bubble level) to facilitate such a level positioning.

When shielding gas weld cone100is properly positioned (or prior thereto), a portion of a welding device (not shown) is inserted through an opening110defined within and extending through shielding gas weld cone100. A plurality of set screws (or similar)112extending through cap120is usable to temporarily secure shielding gas weld cone100to the welding device. Additionally, an O-ring190(FIGS. 4 and 5) may be included to produce a seal between shielding gas weld cone100and the welding device.

After the welding device is positioned with respect to shielding gas weld cone100, a supply of shielding gas “SG” is engaged with inlets140a,140b. The shielding gas “SG” gas then flows through inlets140a,140b, through apertures142, and accumulates within reservoir132. Gravity keeps shielding gas “SG” within reservoir132until the amount of shielding gas “SG” exceeds the volume of reservoir132causing the shielding gas “SG” to overflow or flow over proximal-most edge131of lip130. Since shielding gas weld cone100is level, the shielding gas “SG” overflows the entire, annular proximal-most edge131of lip130at the same time or essentially the same time. Thus, reservoir132of cap120is configured to allow the shielding gas “SG” to overflow uniformly over proximal-most edge131of lip130. This uniform overflow or spilling of the shielding gas “SG” results in a curtain-like flow of the shielding gas “SG” along an inner wall164of funnel160. The shielding gas “SG” continues to flow out of a distal aperture166of funnel160, toward and radially surrounding the weld area, which creates curtain of shielding gas “SG” (FIGS. 1 and 2) thereby shielding the weld area from contaminates.

As noted above, funnel160is shown engaging cap120with plurality of magnets180, thereby creating a selective connection therebetween. The selective connection may be helpful when positioning shielding gas weld cone100is a tight location, if a user wants to reposition funnel160, replace a broken funnel160, or use a different size funnel160, for example. Additionally, the connection between cap120and funnel160is designed such that funnel160is able to break away or separate from cap120, thereby reducing the chances that cap120or funnel160becomes damaged during use, reducing the odds that cap120becomes dislodged from the welding device during use, and reducing the likelihood that cap120is moved out of its level position during use, for example.

Further, the present disclosure relates to methods of manufacturing (e.g., surgical instruments20) utilizing the disclosed shielding gas weld cone100. Disclosed methods include positioning shielding gas weld cone100adjacent a weld site such that proximal-most edge131of lip130of cap120is level, engaging a supply of shielding gas “SG” with shielding gas weld cone100, inserting a portion of a welding device within opening110of shielding gas weld cone100, filling reservoir132with shielding gas “AG,” and overflowing reservoir132with shielding gas “SG” thereby creating a uniform curtain of shielding gas “SG” near the weld site. Disclosed methods also include engaging and/or disengaging funnel160with cap120.