Flexible welding nozzle apparatus

Abstract

The nozzle of an inert gas arc-welding gun is flexibly extended by coupling an elongate, tubular electrode between the body of the gun and its nozzle. The electrode is formed of spirally-wound conductive wire capable of being bent into any desired configuration needed for the particular job and of retaining its set disposition. A sleeve binds the wound wire electrode to maintain its circularity during bending and insulation is provided around the sleeve. Welding current is carried by the wire and the welding metal in wire form is passed through the bore of the wound wire. A steel spring coaxial with the electrode guides the welding wire. Inert gas is supplied through a passage provided between the insulation and the sleeve.

We claim: 
     
       1. Flexible apparatus for supplying electrical energy, welding gas and welding wire to the nozzle of a welding gun, said apparatus comprising: an elongate member formed of electrically-conductive wire spirally wound in a circular path to provide a tube-shaped electrode capable of being bent longitudinally and of retaining its bent position,   a flexible support sleeve enveloping said electrode for resisting the tendency of said spiral winding to flatten during bending,   a flexible insulating sleeve protectively surrounding said support sleeve, said sleeves being disposed in a radially-spaced disposition providing a continuous longitudinal path for said welding gas,   welding wire guide means mounted in the bore of said tubular electrode, and   means for operatively coupling one end of the electrode to said gun and the other to said nozzle whereby welding current is supplied to the nozzle through said electrode windings and welding wire fed to the nozzle through said electrode bore.   
     
     
       2. The apparatus of claim 1 wherein said welding wire guide means is in the form of an elongate coil spring extending substantially the length of said electrode bore. 
     
     
       3. The apparatus of claim 1 wherein said elongate electrode member is formed of a plurality of closely-wound solid wires. 
     
     
       4. The apparatus of claim 1 wherein said support sleeve is provided by a layer of glass tape spirally wound about the full length of said electrode member. 
     
     
       5. The apparatus of claim 1 wherein said coupling means includes a pair of electrically-conductive fittings electrically coupled to said electrode, each of said fittings having a circular flange portion of greater diameter than said electrode member, said elongate insulating sleeve having its end portions mounted on said flanges for providing said radial spacing. .Iadd. 6. Flexibly positionable and position retaining apparatus for supplying electrical energy, welding gas and welding wire to the nozzle of a welding gun, said apparatus comprising:   a tubular current carrying electrode member comprising a single layer of a plurality of solid wire strands closely adjacent each other and all tightly wound together to form a helically wound tubular structure having an open center, said structure being capable of being bent longitudinally and retaining its bent configuration,   flexible support means for counteracting crimping of said helically wound tubular structure during bending,   a flexible insulating sleeve disposed about said flexible support means,   welding wire guide means in said tubular structure, and   means for coupling one end of said electrode member to said nozzle and the other end to a source of welding current, welding gas, and welding wire. .Iaddend. .Iadd. 7. Flexibly positionable and position retaining apparatus for supplying electrical energy, welding gas and welding wire to the nozzle of a welding gun, said apparatus comprising:   a tubular current carrying electrode member comprising a single layer of a plurality of solid wire strands closely adjacent each other, said strands being tightly wound together to form a helically wound tubular structure having an open center and to provide a maximum number of turns with a pitch greater than the diameter of said electrode member, said structure being capable of being bent longitudinally and retaining its bent configuration,   flexible support means for counteracting crimping of said helically wound tubular structure during bending,   a flexible insulating sleeve disposed about said flexible support means,   welding wire guide means in said tubular structure, and   means for coupling one end of said electrode member to said nozzle and the other end to a source of welding current, welding gas, and welding wire. .Iaddend. .Iadd. 8. Flexibly positionable and position retaining apparatus for supplying electrical energy, welding gas and welding wire to the nozzle of a welding gun, said apparatus comprising:   a tubular current carrying electrode member comprising a single layer of a plurality of solid wire strands closely adjacent each other, said strands being tightly wound together to form a helically wound tubular structure having an open center and to provide a maximum number of turns with a pitch greater than the diameter of said electrode member, said structure being capable of being bent longitudinally and retaining its bent configuration,   flexible support means for counteracting crimping of said helically wound tubular structure during bending, said flexible support means comprising a member tightly and spirally wound about and binding the outer surfaces of said strands of solid wires,   a flexible insulating sleeve disposed about said flexible support means,   welding wire guide means in said tubular structure, and means for coupling one end of said electrode member to said nozzle and the other end to a source of welding current, welding gas, and welding wire. .Iaddend. .Iadd. 9. Flexibly positionable and position retaining apparatus for supplying electrical energy and welding wire to the nozzle of a welding gun, said apparatus comprising:   a tubular current carrying electrode member comprising about twelve strands of solid wire of about number twelve wire size positioned closely adjacent each other to form a tubular structure having an open center, said structure being capable of being bent longitudinally and retaining its bent configuration,   flexible support means for counteracting crimping of said tubular structure during bending,   a flexible insulating sleeve disposed about said flexible support means,   welding wire guide means in said tubular structure, and   means for coupling one end of said electrode member to said nozzle and the other end to a source of welding current and welding wire. .Iaddend. .Iadd. 10. Flexibly positionable and position retaining apparatus for supplying electrical energy and welding wire to the nozzle of a welding gun, said apparatus comprising:   a tubular current carrying electrode member comprising a single layer of a plurality of solid wire strands of about number twelve size positioned closely adjacent each other to form a tubular structure having an open center, said structure being capable of being bent longitudinally and retaining its bent configuration,   flexible support means for counteracting crimping of said tubular structure during bending,   a flexible insulating sleeve disposed about said flexible support means,   welding wire guide means in said tubular structure, and   means for coupling one end of said electrode member to said nozzle and the other end to a source of welding current and welding wire. .Iaddend.