Patent Description:
TIG welding uses an electrical arc between a non-consumable tungsten electrode and the metal workpiece to produce a weld. Normally, a filler metal is used and this is manually fed along the weld. A welder therefore holds the welding torch with the tungsten electrode in one hand and the filler metal in the other hand. The welding torch includes the means to deliver a shield gas around the weld site, to avoid oxidisation of the workpiece and poor-quality dross-filled welds. TIG welding is used to achieve high-precision welds.

In known welding torches, a ceramic nozzle is provided at the front of the torch, around the electrode. The purpose of the nozzle is to direct the shield gas to the weld site, where it is required to ensure a high-quality weld. Typically, the ceramic nozzle is provided with an internal screw thread, which corresponds with an external thread on the metal collet body, to hold the nozzle onto the front of the torch.

Often the limit on the longevity of the ceramic nozzle is that the screw thread becomes 'gritty' and eventually no longer corresponds properly with the screw thread on the collet body. It is difficult to achieve a good manufacturing tolerance and the ceramic nozzles do not last a long time.

TIG welding torches typically include a hollow back cap to protect the back of the tungsten rod. Although in principle the tungsten is not "consumable" in the same way as the welding rod in MIG welding, the tungsten rod will gradually be used up over time, and so typically rods are supplied in lengths of around <NUM> - <NUM>, and a rod will be fed slowly forward in the welding torch during its lifetime. The welder will choose the length of tungsten he wants to protrude from the front of the torch, depending on the particular operation being carried out. A collet in the welding torch holds the tungsten rod in its desired position during use. Typically, the collet is tightened by compressing it lengthways between a metal collet body with a closed front end from the front, and a back cap which screws on from the rear. Typically, both the metal collet body at the front and the back cap will attach with standard right-hand screw threads. As a result, the collet is subject to twisting during tightening. Overtime, this damages the collet and limits its life.

The back cap must be sealed against the rest of the torch when attached, to prevent leakage of shield gas out of the back of the torch. This is typically achieved by providing an O-ring on the back cap, which seals against a seat on the torch body. Again, high precision manufacture is required to ensure sealing. Any damage can cause leakage of gas from the back of the torch and again this limits the longevity of the back cap and the torch body.

During use, the frontmost parts of the welding torch will get very hot. The tip of the tungsten itself, the front of the collet body, and the ceramic nozzle are directly exposed to the heat from welding. This heat is gradually conducted into the torch body and handle. As the handle heats up, it will become uncomfortable and unsafe to continue welding and the welder must stop to allow the equipment to cool. The shield gas has some cooling effect in addition to its shielding purpose, and some TIG welding torches are water cooled by a continuous flow of water through the body of the torch. However heat still limits the length of time a welder is able to continuously work.

<CIT> describes welding torches having support members to which by threads the nozzle is attached. The support members hold the nozzle in a position spaced from the collar which holds the welding electrode.

"<NPL> includes a cross-section of a known welding torch, showing a collet and collet holder, the nozzle being attached to the collet holder by screw thread.

It is an object of the invention to provide a TIG welding torch with better cooling performance and which uses parts that are longer lasting.

According to the invention, there is provided a TIG welding torch including a torch body, a metallic front section 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 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 attachment, spaced from the metallic front section, and the ceramic nozzle only being in contact with the heat isolation spacer forward of the attachment when the ceramic nozzle is fitted and the torch is ready for use, in which the metallic front section includes a hollow wall which forms 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.

The heat isolation spacer is provided between the metallic front section of the torch and the nozzle, the nozzle bearing against the outside of the heat isolation spacer when fitted.

Preferably, the metallic front section includes a cooling passage for allowing a cooling gas or fluid to flow, the cooling passage extending to a longitudinal point corresponding to the point of attachment between the heat isolation spacer and the metallic front section. Alternatively a thermal break may be provided in the form of a hollow wall in the metallic front section.

The heat isolation spacer is ideally made from a material with relatively low thermal conductivity. For example, stainless steel has been found to be suitable. Stainless steel has a lower thermal conductivity than brass and copper, which are the typical materials for the metallic front section. Preferably, the heat isolation spacer is tapered inwardly towards the front of the torch. The ceramic nozzle may also have a tapered interior profile.

The tapered heat isolation spacer ensures that the nozzle is held centrally and in a stable position relative to the metallic front section of the torch.

Preferably, the heat isolation spacer is attached to the metallic front section of the torch by means of a screw thread. The heat isolation spacer may be screwed up to meet a shoulder on the metallic front section. In some embodiments, the screw thread and the shoulder are the only points of contact between the heat isolation spacer and the metallic front section of the torch. The heat isolation spacer preferably extends forwards, beyond the screw thread. Preferably, at least two thirds of the length of the heat isolation spacer extends in front of the screw thread. However, the section of heat isolation spacer in front of the screw thread is ideally spaced from the metallic front section by, for example, around <NUM>, so there is no direct contact.

Longitudinal slots may be provided along the part of the heat isolation spacer which extends forward of the screw thread. The longitudinal slots allow the heat isolation spacer to be compressed slightly when the ceramic nozzle is positioned over the heat isolation spacer. When compressed the heat isolation spacer will bear outwardly on the ceramic nozzle from the inside of the ceramic nozzle. The ceramic nozzle is therefore retained by the heat isolation spacer, gripping the nozzle from the inside. The part of the heat isolation spacer which extends in front of the screw thread, when formed with slots, in effect is a series of leaf springs which push against the inside of the ceramic nozzle and grip against the internal surface of the ceramic nozzle.

A band made from an elastic material may be provided, one end of the band being stretched around a front end section of the torch body, and the other end of the band being stretched around a rear section of the ceramic nozzle, for providing a gas-tight seal between the nozzle and the torch body.

The band may be made from, for example, silicone. Ribs may be provided on internal surfaces of the band to provide a better grip and a better seal with the torch body and/or the ceramic nozzle. A rib may be provided on the front of the torch body, so that when fitted a rib on the inside of the band sits behind a rib on the outside of the torch body. A rib may similarly be provided on the outside of the ceramic nozzle if required. Preferably, the front exterior part of the torch body which includes the rib and interfaces directly with the band is made from silicone, or some other heat resisting material.

Using a spacer (and possibly a band) to retain the ceramic nozzle onto the torch body has advantages over the known method of using a screw thread, because it provides better thermal performance. Also, the ceramic nozzle may last longer since minor damage which might prevent proper operation of a screw thread will not prevent proper retention of the ceramic nozzle by the heat isolation spacer.

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:.

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

The torch includes a torch body <NUM>. The torch body includes an interface section <NUM> for attaching the torch to a welding machine. The interface section <NUM> includes a cooling liquid inlet <NUM> and a cooling liquid outlet <NUM>, and a shield gas inlet <NUM>. The liquid inlet and outlet <NUM>,<NUM> and the gas inlet <NUM> are all copper tubes. The copper tubes are brazed to a brass body <NUM>. 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.

The brass body extends along the neck section <NUM> and head <NUM> of the torch <NUM>. The brass body <NUM> is overmoulded with an insulating material, for example silicone rubber. The neck section <NUM> includes a location formation <NUM> 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 <NUM>. The insulating casing <NUM> extends from the neck section <NUM> to form a handle on the welding torch.

The brass body <NUM> in the head section <NUM> is hollow, i.e. an aperture passes all the way through the brass body <NUM> along the line indicated A.

The frontmost part <NUM> of the insulated section of the head <NUM> of the torch includes a rib <NUM>. The backmost section of the uninsulated (exposed brass) part of the head <NUM> of the torch includes an external screw thread <NUM>.

To assemble the torch, one of the heat isolation spacers 36a, 36b, 36c is screwed onto the screw thread <NUM> on the front of the brass body <NUM>. 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 <NUM> of the brass body <NUM>. 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 <NUM> on the front of the back cap <NUM>. Therefore, the collet 38a,b,c, torch body <NUM> and back cap <NUM> can all be held together by screwing the internal thread <NUM> of the back cap <NUM> onto the external thread 40a,b,c of the collet 38a,b,c.

When the collet is fitted, a band 46a,b,c can be stretched around the frontmost insulated section <NUM> of the torch body <NUM>. A rib <NUM> on the torch body assists with retaining the band 46a,b,c onto the torch body <NUM>, 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.

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

<FIG> shows the back cap <NUM> 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 <NUM> in use (the bottom end in <FIG>). The back cap is made from plastics, and has a brass threaded insert <NUM> at the open end. The exterior of the open end is tapered. The taper angle α is preferably <NUM> degrees.

The tapered front section of the back cap <NUM> forms a seal against the silicone overmoulding of the torch body <NUM>, when the torch is assembled. The silicone overmoulding of the torch body <NUM> for this reason extends substantially behind the brass body <NUM> of the head <NUM> 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.

<FIG> 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> drawings) and narrower towards the front. Longitudinal slots <NUM> 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 <NUM> 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 <NUM>,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 <NUM>, near the rear end of the heat isolation spacer. The internal screw thread <NUM> corresponds with the screw thread (<NUM>, <FIG>) on the brass body <NUM> of the head <NUM> of the torch, so that the heat isolation spacer may be screwed onto the brass body <NUM>. The heat isolation spacer is designed to provide a thermal break between the nozzle and the body <NUM>, thus preventing heat generated from the welding process from being transmitted to the body <NUM>.

<FIG> shows the collet 38c in more detail. The collet comprises a rear attachment section <NUM>, a central heat sink section <NUM> and a front grip section <NUM>. The rear attachment section <NUM> includes the external screw thread 40c which corresponds with the internal screw thread on the threaded insert (<NUM>, <FIG>) of the back cap (<NUM>, <FIG>,<FIG>). Also, a longitudinal slot <NUM> extends from the rear of the collet 38c, cutting through the screw thread and terminating in front of the screw thread 40c. A rib <NUM> is provided at the end of the screw thread, and the slot <NUM> passes also through the rib <NUM>. The rib <NUM> provides a shoulder to limit how far the collet 38c can be screwed into the back cap (<NUM>).

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

The heat sink section <NUM> of the collet 38c includes spines <NUM>, and channels <NUM> running between the spines <NUM>. In use, shield gas passes through the channels <NUM> on its way from the gas inlet (<NUM>) and out of the front of the nozzle (48c). This assists with cooling the torch.

The front grip section <NUM> of the collet 38c is the part which grips the tungsten rod when the collet 38c is closed. A tapered section <NUM> is provided, which is wider towards the front of the collet 38c and narrower towards the rear. In use, the tapered section <NUM> passes into the front of the aperture in the brass body (<NUM>) of the head (<NUM>) of the torch. As the collet 38c is drawn backwards by tightening the screw thread 40c onto the back cap <NUM>, wider and wider parts of the tapered section <NUM> are drawn into the aperture in the brass body (<NUM>) of the head (<NUM>). This closes the jaws of the collet 38c to retain the tungsten rod. Preferably, the front opening of the aperture in the brass body (<NUM>) is internally tapered to match the taper <NUM> 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 <NUM> is just in line with the opening of the body (<NUM>) of the head (<NUM>), to a closed position where the front edge of the tapered section <NUM> is recessed within the opening of the body (<NUM>) of the head (<NUM>) by for example <NUM>. In front of the front edge of the tapered section <NUM>, an undercut <NUM> is provided. The undercut <NUM>, together with longitudinal slots <NUM> through the tapered section <NUM>, provide gas flow channels to allow shield gas to flow from the channels <NUM> of the heat sink section <NUM>, through the front of the collet 38c and out of the nozzle.

<FIG> show an alternative collet 38b. The collet 38b again has an attachment section <NUM> and a heat sink section <NUM>. These parts are substantially identical to those of the collet 38c in <FIG>. The grip section <NUM> likewise includes a tapered section <NUM>, an undercut <NUM> and longitudinal slots <NUM>. However, this alternative collet 38b is provided with an integrated gas lens <NUM>. The gas lens <NUM> is of a known type - a 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 <NUM> 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 <NUM> 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.

<FIG> shows the welding torch of <FIG>, when fully assembled. Parts of the torch are cut away so that gas and liquid flows can be seen.

The band 46c is seen fitted in <FIG>, 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.

At the back of the torch body, a pin <NUM> is visible. The pin <NUM> corresponds with the slot (<NUM>) 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> is the extent of the silicone overmoulding behind the brass body <NUM> of the torch head <NUM>. The silicone overmoulding extends behind the brass body <NUM> by almost the extent of the tapered section of the back cap <NUM>. With the back cap <NUM> fully tightened onto the collet 38c, the tapered section of the back cap <NUM> forms a gas-tight seal with the silicone overmoulding of the torch head <NUM>, preventing any leaking of shield gas out of the back of the torch.

The front section of the brass body <NUM> of the torch is also shown in cross-section, and the tapered entrance which corresponds to the tapered section <NUM> of the collet 38c is visible.

The flow of inert shield gas through the welding torch <NUM> is indicated by arrows. From the end of the inlet tube <NUM> at the top of the neck (to the left of <FIG>), shield gas flows in the channels (<NUM>) of the collet 38c, between the collet 38c and the inside wall of the brass body of the torch head <NUM>. The gas then flows through the slots (<NUM>) 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 <NUM>, at the very front of the undercut (<NUM>) in the collet 38c. The gas is then directed towards the workpiece by the nozzle 48c.

The brass body <NUM> of the head <NUM> of the torch <NUM> has a hollow wall. This forms a liquid-filled jacket which allows cooling liquid to pass from liquid inlet <NUM>, into the hollow wall of the brass body, and then out of the liquid outlet <NUM>. The liquid jacket is indicated at <NUM>.

The heat isolation spacer 36c is shown installed on the torch with the thread <NUM> screwed onto the brass torch body <NUM>. It is apparent from the cross section in <FIG> that the heat isolation spacer <NUM> is only in contact with the brass body at the thread <NUM>, and just to the rear of the thread. The parts of the heat isolation spacer 36c which are forward of the thread <NUM> are spaced from the brass body <NUM>. 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.

<FIG> shows the gas-cooled version of the torch of <FIG>. Again, arrows show the flow of gas through the torch. The gas flow is identical to that in the torch of <FIG>, 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>, but equally the collet 38c without the gas lens could be fitted to the gas-cooled torch <NUM>'.

The construction of the brass body <NUM> of the torch <NUM>' is again almost identical to that of torch <NUM>. The brass body <NUM> still has a hollow wall, although no liquid flows within the cavity. Instead, the hollow cavity <NUM> in the brass body <NUM> 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 <NUM> and then to the handle of the torch <NUM>'. Again, the heat isolation spacer 36b is only in contact with the brass body <NUM> over a very small area, and the area of contact is substantially central on the extent of the hollow thermal break <NUM>.

The torches <NUM>, <NUM>' 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 <NUM> is resisted very close to the back cap <NUM> longitudinally, by the pin <NUM> in the slot <NUM>.

The gas seal at the back of the torch <NUM>, <NUM>' is also more reliable and longer lasting than in known designs. The tapered front section of the back cap <NUM>, which seals against the silicone overmoulding behind the back of the brass body <NUM>, provides a high-quality seal.

Finally, the torch <NUM>, <NUM>' 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.

Claim 1:
A TIG welding torch (<NUM>) including a torch body (<NUM>), a metallic front section of the torch body 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 heat isolation spacer (36a,b,c) being attached 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 attachment, spaced from the metallic front section, and the ceramic nozzle (48a,b,c) only being in contact with the heat isolation spacer (36a,b,c) forward of the attachment when the ceramic nozzle (48a,b,c) is fitted and the torch (<NUM>) is ready for use, in which the metallic front section includes a hollow wall which forms 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 (36a,b,c) and the metallic front section.