Abstract: A connector assembly for releasably securing a welding torch to an extended end portion of a power cable assembly having an outer hose disposed about an electrically conductive cable for directing gas therethrough to the torch. An aperture is provided in the side wall of an electrically conductive tubular member between upstream and downstream portions thereof. An upstream portion of the tubular member is crimped about an end of the cable so as to define a generally U-shaped trough extending along the upstream portion of the tubular member, creating a gas flow path extending therealong to and through the aperture, into and through the downstream portion of the tubular member. A hose attachment sleeve is rotatably and sealably mounted on a pair of axially spaced sealing members on the downstream portion of the tubular member so that the torch can be rotated with respect to the hose during use, reducing strain on the welder.

Abstract: A power cable for use with welding apparatus for conveying power and cooling fluid from a welding machine to a welding torch. The cable includes an outer flexible conduit disposed about a flexible electrical conductor, a pair of end fittings operatively connected to the ends of the conduit and an electrical conductor for securing the power cable between the welding torch and welding machine in fluid and electrical communication therewith. The flexible conduit includes an inner tube portion formed of a flexible non-conductive rubber compound, a protective cover layer comprised of a plurality of threads braided or woven about the inner tube portion and a thin coating of a heat and wear resistant material such as polyurethane disposed over the braided or woven threads for bonding the protective cover layer to the inner tube portion, rendering the power cable heat and wear resistant without adversely affecting the flexibility thereof.

Abstract: A power cable assembly for use in a water and air-cooled welding assemblies for carrying power from a welding machine to a welding torch and either cooling water from the torch to a circulator reservoir or, in the case of air-cooled torches, shielding gas to the torch. The cable assembly includes a flexible outer conduit disposed about a flexible electrical conductor formed of a plurality of twisted, braided or bunched wires encased in a thin layer of flexible plastic material. A plurality of projections extend radially from the flexible encasement so as to space the electrical conductor from the interior conduit wall, thereby defining a water or gas-flow path extending entirely about the conductor.

Abstract: A power cable adapter for use with a welding torch assembly to electrically couple the power cable in the cable carrying line with the power output stud on the welding machine and communicate the cable carrying line with a fluid supply line for the passage of fluid therethrough. The adapter includes a pair of clam shell type clamp members formed of an electrically conductive material. The clamp members define aligned apertures therein for securing the adapter on the output stud and at least one of the clamp members defines an open channel extending laterally thereacross for adjustably securing an electrically conductive U-shaped tube in electrical contact with the clamp members. Connector fittings are provided on the ends of the tube for communication with the torch lines, allowing the torch lines to extend to and from the adapter in a parallel orientation at any desired angular orientation from the welding machine.

Abstract: An improved welding torch wherein the connection between the torch body and handle is a frictional engagement and prevents any relative rotational movement of the torch handle and body while additionally providing an indexing mechanism for selective alignment of the torch body with a variety of surface contours on the torch handle. The torch body includes a plurality of radially projecting handle engagement ribs thereon and a radially projecting indexing pin receivable in one or more axial grooves in an end wall of the handle. The grooves are radially aligned with different surface contours on the handle such that when the handle is in place on the torch body, the ribs frictionally engage the handle and the indexing pin is disposed in one of the grooves preventing inadvertent relative rotation of the torch handle and body and aligning a selected handle contour with the torch body.

Abstract: A gas lens assembly for use in a gas shielded welding torch to provide laminar gas flow to the weld puddle. The assembly includes a plurality of annular fine mesh inner filter screens mounted in fixed axially spaced disposition in a gas chamber formed between the lens body and lens sleeve. The filter screens are preferably spaced apart a predetermined distance by a plurality of wave-shaped open mesh spacer discs disposed in a sandwich configuration between the filter screens. A stack of adjacently disposed outer filter screens are mounted in the gas chamber outwardly of the fine mesh filter screens. Each of the outer screens in the stack is individually removable such that the outermost screen can be readily peeled from the stack when damaged by spatter or heat to maintain the laminar gas flow through the assembly and prolong the useful life of the assembly.

Abstract: A cable cover for use with welding and cutting apparatus to protect and bundle together the power and any fluid-carrying lines extending from the torch handle. The cover includes an elongated panel formed of a flexible and durable material and having substantially parallel edge portions adapted to be secured together about the torch lines. A zipper is carried by the edge portions for securing those edge portions together over a first major portion of the cover. Strips of hook and loop fasteners are carried by the edge portions of the panel over the last two to three feet of the cover. Thus, a major portion of the cover can be quickly secured about the torch lines using the zipper fastener and one or more torch lines can exit the cover laterally at desired locations through the hook and loop fastener proximate the power supply without adversely impacting the integrity of the cover.

Abstract: A gas lens assembly for use in a gas shielded welding torch to provide laminar gas flow to the weld puddle. The assembly includes a plurality of annular fine mesh inner filter screens mounted in fixed axially spaced disposition in a gas chamber formed between the lens body and lens sleeve. The filter screens are preferably spaced apart a predetermined distance by a plurality of wave-shaped open mesh spacer discs disposed in a sandwich configuration between the filter screens. A stack of adjacently disposed outer filter screens are mounted in the gas chamber outwardly of the fine mesh filter screens. Each of the outer screens in the stack is individually removable such that the outermost screen can be readily peeled from the stack when damaged by spatter or heat to maintain the laminar gas flow through the assembly and prolong the useful life of the assembly.

Abstract: A power cable adapter for use with a welding torch assembly to electrically couple the power cable in the cable carrying line with the power output stud on the welding machine and communicate the cable carrying line with a fluid supply line for the passage of fluid therethrough. The adapter includes a pair of clam shell type clamp members formed of an electrically conductive material. The clamp members define aligned apertures therein for securing the adapter on the output stud and opposed channels extending laterally therethrough for adjustably securing an electrically conductive U-shaped tube in electrical contact with the clamp members. Connector fittings are provided on the ends of the tube for communication with the torch lines, allowing the torch lines to extend to and from the adapter in a parallel orientation at any desired angular orientation from the welding machine.

Abstract: An improved gas shielded welding torch having a head portion adopted to retain a tungsten electrode therein and flexible handle portion which supplies electric current and inert shielding gas to the head portion. The handle portion includes a bendable metal helix of solid wire therein which defines an electrically conductive path through the handle portion and renders the handle portion readily bendable so that the torch head can be positioned in any desired angular orientation with respect thereto to facilitate access to the work area. A torch body of elastomeric insulating material is molded about the helix and adjacent portions of the torch handle.

Abstract: Disclosed herein is a gas shielded welding torch of the TIG type, having a removable head portion to readily accommodate heads of different angular configurations. The torch includes a body portion which can be either air or water cooled, a removable head portion threadably engaged with the body portion, a nozzle, an electrode assembly carried within the head portion and means for directing an inert gas to the nozzle and electrical current to the electrode.