The present disclosure relates generally to oxy-fuel torches and more particularly to oxy-fuel torches having built-in electrical ignition systems, or auto-ignition systems.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Oxy-fuel torches, or gas torches, generally employ oxygen and a fuel gas, such as acetylene or propane, by way of example, to cut or heat a workpiece. More specifically, preheat oxygen and the fuel gas are mixed and ignited to provide heat to the workpiece, and then additional oxygen, commonly referred to as cutting oxygen, is added to react with the heated workpiece. This reaction of the cutting oxygen with the heated workpiece initiates sufficient heat and momentum of the gases to initiate a cutting process.
To ignite the preheat oxygen and fuel gas, a “striker” is often used, which is a device that creates a spark for ignition. The operator typically adjusts the flow of preheat oxygen and fuel gas for ignition, and then while holding the torch in one hand uses the other hand to operate the striker at another end of the torch. Once the gases are ignited, the operator then stores the striker and further adjusts the flow of gases in order to optimize the flame and initiate the cutting process. Therefore, starting a gas torch requires the use of two hands and is often cumbersome and time consuming for the operator. Additionally, operators often use other ignition devices that may not be safe, such as a cigarette lighter or even a cigarette that extends from the mouth of the operator.
There exist some auto-ignition gas cutting torches in the field, which typically employ a piezoelectric igniter and spark source near the handle of the torch. In this way, a separate striker or ignition source is not required, and an operator can more easily ignite the torch. However, such gas cutting torches include controls that are often difficult to manipulate, are tiring to use over time, and lack certain safety features.
During operation, undesirable gas mixtures and flames can travel back through the torch and the gas hoses and present safety concerns. One such scenario is often referred to as “flashback,” which occurs when flames from the cutting torch travel back into the gas hoses. Another scenario is referred to as “backfire,” in which the combustible mixture of gases flows back into the torch and causes a sudden “popping” noise/effect in of the torch. Yet another scenario is “sustained backfire,” where the combustible mixture of gases is constantly being fed back into the torch and a constant “popping” occurs, and thus the torch does not operate properly. When inadvertent flashback or combustion occurs within or near the gas cutting torch, operators often drop the gas cutting torch without shutting off the gas supplies in an immediate reaction to escape any perceived harm. Additionally, operators often drop the gas cutting torch in certain circumstances when their attention is needed, such as to attending to a coworker that is in need of help, or when breaking a fall, by way of example. When the gas cutting torch is dropped without properly shutting off the gas supplies, dangerous situations may occur, such as explosions, fires, in addition to causing damage to the torch itself. Therefore, some conventional gas cutting torches can be dangerous if not operated properly or if not designed properly.
With the inherent difficulties in starting and operating gas cutting torches and the attendant dangers of operation, improved ergonomic and human factor designs and safety features are continuously desired in the field of gas cutting torches. Moreover, productivity enhancements and ways in which to reduce the amount of gas that is wasted during operation are also desirable.
In one form, the present disclosure provides a gas torch comprising an auto-ignition system disposed within the gas torch, a preheat oxygen conduit array extending through the gas torch, a fuel gas conduit array extending through the gas torch, and a cutting oxygen conduit array extending through the gas torch. At least one safety device is disposed within the gas torch, along with a cutting oxygen trigger, and an ignition trigger operable to start preheat gas flow and to ignite the gas torch. The ignition trigger is configured for automatic disengagement of the auto-ignition system when the ignition trigger is released.
In another form of the present disclosure, a gas torch is provided that comprises an auto-ignition system disposed within the gas torch, a preheat oxygen conduit array extending through the gas torch, a fuel gas conduit array extending through the gas torch, and a cutting oxygen conduit array extending through the gas torch. A plurality of check valves are disposed within the gas torch, along with a plurality of flashback arrestors, which act as safety devices. The gas torch also includes a cutting oxygen trigger and an ignition trigger operable to start preheat gas flow and to ignite the gas torch. The ignition trigger is configured for automatic disengagement of the auto-ignition system when the ignition trigger is released.
In still another form, a gas torch is provided that comprises an auto-ignition system disposed within the gas torch, at least one safety device disposed within the gas torch, a cutting oxygen trigger, and an ignition trigger operable to start preheat gas flow and to ignite the gas torch, the ignition trigger configured for automatic disengagement of the auto-ignition system when the ignition trigger is released.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the embodiments of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
a is a front view of the first plate seal and its gas channels constructed in accordance with the principles of the present disclosure;
b is a rear view of the first plate seal and its gas channels constructed in accordance with the principles of the present disclosure;
a is a front view of the second plate seal and its gas channels constructed in accordance with the principles of the present disclosure;
b is a rear view of the second plate seal constructed in accordance with the principles of the present disclosure;
a is a cross-sectional view through the handle section and ignition trigger, illustrating a latch of the ignition trigger in an “off” position and constructed in accordance with the principles of the present disclosure;
b is a cross-sectional view through the handle section and ignition trigger, illustrating a latch of the ignition trigger in an “on” position and constructed in accordance with the principles of the present disclosure;
c is several 3D views of various components of the ignition trigger constructed in accordance with the principles of the present disclosure;
a is a perspective bottom left side view of certain components of a trigger system and the purge selector constructed in accordance with the principles of the present disclosure;
b is a perspective bottom right side view of the components of a trigger system and the purge selector in accordance with the principles of the present disclosure;
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
The following description of the embodiments is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses.
Referring to
As further shown, a first plate seal 52 is disposed between the handle portion 22 and the flow control unit 36, a second plate seal 54 is disposed between the handle portion 22 and the tube section 38, and a third plate seal 56 is disposed between the head portion 44 and the cutting tip 46, and more specifically, the tip seat 48. The plate seals 52, 54, and 56 generally function to direct or channel a flow of oxygen and fuel gas, as described in greater detail below, and also to seal the interfaces between the various components of the gas cutting torch 20.
Additionally, with reference to
Referring now to
The conduit arrays 70, 72, and 74 are now described in greater detail as they pass through various components of the gas cutting torch 20. Referring first to
The fuel gas conduit array 72 extends from the fuel gas inlet port 78, through a preheat fuel gas metering device 82 (shown in
The cutting oxygen conduit array 74 extends from the oxygen inlet port 76, through the flow control unit 36, and out the flow control unit 36 as shown. The cutting oxygen conduit array 74 then extends to the first plate seal 52 and follows a channel 88 from the front side of the plate seal 52 to the back side of the plate seal 52 as shown in
Moving now to the handle section 22, and with reference to
Referring now to
From here, the conduit arrays continue on to the tube section 38, as shown in
As shown in
Referring back to
The plate seals 52, 54, and 56 also include sealing portions 118, which are generally an elastomeric material and extend or protrude from the faces of the plate bodies 104, 106, and 108. These sealing portions 118 are generally defined by the shape of the channels and gas passageways as shown. When the plate seals 52, 54, and 56 are secured to and tightened against their adjacent components (flow control unit 36, handle portion 22, tube section 38, and tip seat 48), the sealing portions 118 are compressed and thus form a seal at their interfaces. In this way, use of plate seals 52, 54, and 56 are highly advantageous since they eliminate the use of complicated forgings and machinings and also eliminate the associated brazing or soldering processes. In one form of the present disclosure, each of the gas passageways for the preheat oxygen conduit array 70, the fuel gas conduit array 72, and the cutting oxygen conduit array 74 are formed perpendicular to the faces through which they travel. Therefore, the components of the gas cutting torch 20 are much simpler and cost effective than the prior art.
Referring now to
As further shown, the ignition trigger 32 also comprises a latch 126 disposed within a groove 128 in the trigger body 120. Generally, the latch 126 is slidably engaged within the groove 128 along the direction of arrow A. (See
The latch 126 further comprises an upper extension 130 that is adapted to prevent the trigger body 120 from engaging the ignition system 60 without sliding the latch 126. Furthermore, the latch 126 is adapted to be received within a cavity 132 formed in the handle body. The upper extension 130 defines a ramped surface 134 that cooperates with a corresponding ramped surface 136 of the cavity 132 in the “on” position, the operation of which is described in greater detail below. In the “off” position, the upper extension 130 abuts an inner surface 140 of the handle body 23 such that the trigger body 120 cannot be moved in the direction of arrow B and thus engage the ignition system 60.
Also included with the ignition trigger 32 is a biasing device 138, which in one form is a coil spring as shown, which biases the ignition trigger 32 in the “off” position. More specifically, as shown in
The ignition system 60 within the handle portion 22 includes a piezoelectric igniter 142 with a piston 144 extending therefrom. Additionally, gas control devices are disposed within the handle portion 22, and more specifically, a first gas control device 146 to control the flow of preheat oxygen, and a second gas control device 148 to control the flow of fuel gas. In one form, the gas control devices 146 and 148 include Schrader valves, however, it should be understood that other types of gas control devices may be employed while remaining within the scope of the present disclosure. Additionally, in an alternate form, the gas control devices 146 and 148 may be combined with the preheat oxygen and preheat fuel metering devices, 80 and 82 respectively, in order to reduce the number of gas control devices and thus the complexity of the gas cutting torch 20. The trigger body 120 defines internal receptacles 149 that are adapted to receive the gas control devices 146 and 148. Additionally, as best shown in
Additionally, the trigger system 30 includes an interlock device 135 (which in this form is a pin as shown) that is secured to the cutting oxygen trigger 34 and functions to prevent the flow of cutting oxygen when the ignition trigger 32 is not engaged, which is described in greater detail below. A wedge block 137 is also provided as a part of the ignition trigger 32, which cooperates with the forward portion 122 and a spring plunger 133 to reduce the amount of force that is required to hold the ignition trigger 32 in the “on” position. More specifically, and with reference to
In operation, an operator slides the latch 126 back and pulls up on the trigger body 120. The trigger body 120 pivots about the hinge portion 150, and the internal receptacles 149 engage the gas control devices 146 and 148, and the flow of preheat oxygen and fuel gas are initiated. Further, the cam surface 124 of the forward portion 122 of the trigger body 120 engages the piston 144 of the piezoelectric igniter 142, and an ignition source is generated, which travels down the length of the ignition wire 64 to the cutting tip 46 (not shown) to start the gas cutting torch 20. The piston 144 is further engaged within the detent 123 of the ignition trigger 32 forward portion 122, and the interlock pin 135 is allowed to travel, thus permitting operation of the cutting oxygen trigger 34 and the flow of cutting oxygen. Additionally, the spring plunger 133 engages the detent 139 of the wedge block 137 to reduce operator fatigue as previously set forth. When an operator releases the latch 126, the biasing device 138 forces the trigger body 120 back down to its neutral, or “off” position. In this position, it should be further noted that travel of the trigger body 120 is limited by a protective member 152, wherein the forward portion 122 of the ignition trigger 32 abuts the protective member 152 as shown.
In summary, the ignition trigger 32 according to the present disclosure initiates the flow of preheat oxygen and fuel gas, while also initiating ignition with a single motion by the operator. Therefore, the gas cutting torch 20 can advantageously be started with the use of only one-hand, or in other words, is configured for single-hand operation once the preheat oxygen and preheat fuel are properly set. Additionally, the ignition trigger 32 is configured for “auto shut-off” as set forth above, wherein the gas cutting torch 20 automatically shuts off when the ignition trigger 32 is released, whether intentionally or accidentally, thus improving the safety of the gas cutting torch 20.
The trigger system 30 also includes the cutting oxygen trigger 34, which is preferably mounted to an upper distal end of the handle portion 22 as shown. As best shown in
As further shown, a purge selector 170 is also disposed within the handle portion 22. The purge selector 170 is slidably mounted to the handle body 23 and thus slides from left to right when depressed or pushed from either side. Referring specifically to
Referring now to
As further shown, the tube section 38 further comprises a plurality of check valves 210, 212, and 214, each disposed at the proximal end portion 40 and distally from the second plate seal 54. The check valves 210, 212, and 214 are each disposed within the fuel gas conduit array 72, the cutting oxygen conduit array 74, and the preheat oxygen conduit array 70 as shown. These check valves 210, 212, and 214 and are yet another safety feature of the gas cutting torch 20, in that any gas flow back towards the handle portion 22 is prevented through the use of the check valves 210, 212, and 214. The check valves 210, 212, and 214 are also readily interchangeable and are positioned for ease of repair or replacement.
The tube section 38 also includes a head cover 220, which is interchangeably secured to the gas cutting torch 20 proximate the head portion 44. The head cover 220 provides protection for the head portion 44 of the gas cutting torch 20, such as when a user unwittingly employs the gas cutting torch 20 as a hammering device, or when a user is attempting to remove slag or other debris from the gas cutting torch 20. Additionally, various graphics or indicia may be provided on the head cover 220, including a company logo as shown, among others. As such, the head cover 220 provides both protection and a unique physical appearance that can be customized for each end user.
Referring back to
Turning now to
Referring to FIGS. 1 and 31-33, the tip seat 48 is illustrated and now described in greater detail. The tip seat 48 includes four (4) mounting holes 250, through which mechanical fasteners secure the tip seat 48 to the head portion 44 of the gas cutting torch 20. In this way, the tip seat 48 is interchangeable such that different tip seats may be employed according to different application requirements. The tip seat 48 also comprises gas passageways 252, 254, and 256 that form a part of the conduit arrays for the fuel gas, cutting oxygen, and preheat oxygen, respectively. The tip seat 48 further comprises a base portion 258 and an annular extension 260. The annular extension 260 comprises a plurality of annular ridges 262, 264, and 266, which separate and seal the flows of cutting oxygen, fuel gas, and preheat oxygen. Additionally, a recess 268 is formed at a distal end of the annular extension 268 to accommodate the cutting tip 46, which is described in greater detail below. The cutting tip 46 is secured to the tip seat 48 with a locking nut 270, which is shown in
Referring now to
As shown in
An annular preheat oxygen gas passageway 316 is defined between an inner surface 318 of the outer shell 302 and an outer surface 320 of the cap 304. This preheat oxygen gas passageway 316 is in fluid communication with the preheat oxygen gas passageways 310 formed through the insert 308, thus providing for the flow of preheat oxygen through the post-mix cutting tip 300. An annular fuel gas passageway 322 is formed between an inner surface 324 of the cap 304 and outer surfaces 326 of the inner tube 306. The annular fuel gas passageway 322 is in fluid communication with the fuel gas passageways 312 formed through the insert 308 and with the fuel gas passageways 313 formed through the inner tube 306, thus providing for the flow of fuel gas through the post-mix cutting tip 300. Advantageously, with fuel gas passageways 313 formed through the inner tube 306, the flow of fuel gas provides additional cooling to the inner tube 306 during operation. A central passageway 328 is formed through the inner tube 306 for the flow of cutting oxygen, which is in fluid communication with the cutting oxygen gas passageway 314 formed through the insert 308, thus providing for the flow of cutting oxygen through the post-mix cutting tip 300. In operation, the preheat oxygen, fuel gas, and cutting oxygen flow through separate gas passageways as set forth above and are not mixed together until they meet at the distal end portion 315 as shown. Accordingly, the gases are mixed at the distal end portion 315 to provide the post-mix feature, while the spark is generated across the gap “G,” thereby providing both another safety feature and a convenience feature to the gas cutting torch 20.
It should be understood that the spacing between components of the post-mix cutting tip 300 and the angles of the cap 304 surfaces and outer shell 302 surfaces may be varied to achieve certain flame characteristics. Additionally, although the front faces of the inner tube 306 and the outer shell 302 are shown as being flush, they may also be offset from one another (in either direction) while remaining within the scope of the present disclosure.
In one form, the insert 308 is a high temperature plastic, such as PEEK (Polyetheretherketone) thermoplastic, and could alternately be a ceramic material, among others. The inner tube 306 is conductive and in one form is a brass alloy. Similarly, the outer shell 302 is conductive and is also a brass alloy. The cap 304 is a steel alloy in one form of the present disclosure. It should be understood that these materials are merely exemplary and that other materials may be employed while remaining within the scope of the present disclosure.
As shown in
As shown in
An annular preheat oxygen gas passageway 416 is defined between an inner surface 418 of the outer shell 402 and an outer surface 420 of the cap 404. This preheat oxygen gas passageway 416 is in fluid communication with the preheat oxygen gas passageways 410 formed through the insert 408, thus providing for the flow of preheat oxygen through the post-mix cutting tip 400. An annular fuel gas passageway 422 is formed between an inner surface 424 of the cap 404 and outer surfaces 426 of the inner tube 406. The annular fuel gas passageway 422 is in fluid communication with the fuel gas passageways 412 formed through the insert 408, thus providing for the flow of fuel gas through the post-mix cutting tip 400. A central passageway 428 is formed through the inner tube 406 for the flow of cutting oxygen, which is in fluid communication with the cutting oxygen gas passageway 414 formed through the insert 408, thus providing for the flow of cutting oxygen through the post-mix cutting tip 400. In operation, the preheat oxygen, fuel gas, and cutting oxygen flow through separate gas passageways as set forth above and are not mixed together until they meet upstream of the distal end portion 315 as shown. The preheat oxygen and the fuel gas are mixed first and then this mixture travels through annular mixture passageway 430 towards the exit where cutting oxygen exits the post-mix cutting tip 400. Accordingly, the gases are mixed near the distal end portion 315 to provide the post-mix feature, while the spark is generated across the gap “G,” thereby providing both another safety feature and a convenience feature to the gas cutting torch 20.
It should be understood that the spacing between components of the post-mix cutting tip 400 and the angles of the cap 404 surfaces and outer shell 402 surfaces may be varied to achieve certain flame characteristics. Additionally, although the front faces of the inner tube 406 and the outer shell 402 are shown as being flush, they may also be offset from one another (in either direction) while remaining within the scope of the present disclosure.
In one form, the insert 408 is a high temperature plastic, such as PEEK (Polyetheretherketone) thermoplastic, and could alternately be a ceramic material, among others. The inner tube 406 is conductive and in one form is a brass alloy. Similarly, the outer shell 402 is conductive and is also a brass alloy. The cap 404 is a steel alloy in one form of the present disclosure. It should be understood that these materials are merely exemplary and that other materials may be employed while remaining within the scope of the present disclosure.
It should also be appreciated from the present disclosure that the tips illustrated and described perform a dual-function, in that they distribute (and in one form mix) the fuel gas, the preheat oxygen, and the cutting oxygen, while also serving as an ignition source. Such a design is advantageous because the tip is a consumable component, and as such, is often replaced after repeated use. When the tip is replaced, the ignition source is also replaced, which results in a tip with improved performance. Moreover, the present disclosure is not to be viewed as limited to post-mixed cutting tips, and rather, tips that merely distribute gases but also function as an ignition source are also to be construed as falling within the scope of the present disclosure.
Operation
Referring back to
The other safety features, namely, the check valves 210, 212, and 214 in the tube section 38, the flashback arrestors 192, 194, and 196 in the tube section, the post-mix cutting tips 300 and 400, the automatic shut-off features, the cutting oxygen interlock pin 135, and the sequencing of gas and ignition, provide an unprecedented level of safety not heretofore provided in gas cutting torches in the art. Along with the single-handed operation, the ergonomic features, and the interchangeability of components, (which is set forth in greater detail below), the gas cutting torch 20 according to the present disclosure provides significant improvements and advantages over gas cutting torches in the art. The gas cutting torch 20 can be used right where an operator needs to perform cutting operations and does not require a separate lighting step away from the workpiece and then moving the gas cutting torch 20 into place. Such prior art practice of lighting a torch away from a workpiece using a striker, and then moving the torch to the cutting location, can be dangerous, especially in tight quarters and/or where other items from the surrounding environment may become inadvertently damaged or destroyed during movement of the torch to the cutting location. As such, the gas cutting torch 20 according to the present disclosure provides increased efficiency to the operator as they are able to be more nimble and quick with their cutting operations.
Advantageously, each of the components of the gas cutting torch 20, namely, the flow control unit 36, the handle portion 22, the palm grip 240 of the handle portion 22, the tube section 38, and the tip seat 48 are interchangeably secured such that repair or replacement is easily accomplished. Depending on the needs of the end user and/or the application requirements, different configurations for each of these components may be desired, and thus the modular or interchangeable nature of these components provides additional flexibility and capability not seen in prior art gas cutting torches. Although mechanical fasteners are used to remove and replace these components, it should be understood that other forms of securing these components may be employed while remaining within the scope of the present disclosure. Additionally, components that are ambidextrous or that are tailored for either left handed or right handed operators may be employed while remaining within the scope of the present disclosure.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the invention. For example, the number of components as illustrated herein may be reduced through a “design-for-manufacturing and assembly” (DFMA) exercise, and thus combining or reducing the number of components shall be construed as falling within the scope of the present disclosure. Other such variations are not to be regarded as a departure from the spirit and scope of the invention. For example, it is contemplated that the gas cutting torch 20 may include an articulating head portion such that various angles can be achieved to accommodate cutting applications with limited access.
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