CROSS-REFERENCE TO RELATED APPLICATION

[0001] This International application claims the benefit/priority to U.S. Provisional Application No. 63/413,051 filed October 4, 2022, the disclosure of which is expressly incorporated by reference herein in its entirety.

BACKGROUND

1. FIELD OF THE INVENTION

[0002] A device or tool for removing/replacing an electrode in a thermal spray gun that includes a wrench.

2. DISCUSSION OF BACKGROUND INFORMATION

[0003] The electrode in a thermal spray gun requires periodic replacement. In the know process for replacing thermal spray gun electrodes, a first device or tool is used to unlock, unscrew or remove a retaining ring or similar mechanism that constrains the electrode in the thermal spray gun, and a second device or tool is used to grip the electrode in order remove the electrode from the gun. The second device or tool for removing the electrode, e.g., can grip the electrode so that a longitudinal pulling force can be applied to the electrode in order to pull the electrode through an opening in the gun, or can grip the electrode so that a twisting or rotational force can be applied to the electrode in order to unscrew the electrode for removal through the gun opening.

[0004] In conventional operation, for example in a 9MB thermal spray gun made my Oerlikon Metco(US) Inc., an electrode spanner wrench is used to remove an electrode holding nut, then a second tool, an electrode puller pliers, is used to remove the electrode. In Fig. 1, the two separate tools required for removing an electrode from a thermal spray gun are shown. Electrode spanner wrench 11 is designed to loosen for removal a retaining ring or similar mechanism specially designed and provided to constrain or retain the electrode within the thermal spray gun. Electrode puller pliers 12 allow a user to grip the electrode for removal of the electrode from the thermal spray gun. In order to remove the electrode in a gun chamber, a longitudinal or pulling force can be applied to the electrode through an opening in the thermal spray gun, or a twisting or rotational force can be applied to the electrode through the gun opening to unscrew the electrode from the gun chamber.

[0005] Conventional puller pliers, due to the characteristics of the front section, require that the tip, which can be a part brazed to the pliers tip, be extended in order to reach the electrode. Even with the extended tip, the electrode could sometimes still not be fully grabbed before being removed.

[0006] Discontinuation of pliers by several vendors, led to the modification of several components dimensions to accommodate a new pliers. This resulted in complaints from the field, assembly plant & customers for not getting a good grip of the electrode before removing it.

[0007] Accordingly, there is a need for a new tool that improves the functionality of the individual known tools, thereby improving efficiency of usage, inventory reduction and cost savings by, e.g., consolidation of these two tools in one tool, which would eliminate inventory for a second tool and improve the ergonomic usage by using the same tool for both tasks, rather than having to put away the first tool while looking for the second tool.

SUMMARY

[0008] Accordingly, in embodiments, a new electrode removal tool is provided that consolidates the two separate conventional tools into a single, multi-functional tool or device.

[0009] The electrode removal tool includes both tools in the known art into a single tool or device so that a spanner wrench or other similar tool, e.g., an electrode spanner wrench on a first end and a puller jaw on an opposite or second end.

[0010] In embodiments, the electrode removal tool eliminates or at least reduces the risk of scratching or damaging the components, as well as preventing or avoiding electrical arcing.

[0011] With the electrode removal tool according to embodiments, the second end, which can be easily inserted into the gun opening to reach the electrode, includes a retractable jaw that can securely grip the electrode before a longitudinal or pulling/pushing force is applied through the opening in the thermal spray gun in order to the electrode in order to remove or seat the electrode within the gun chamber.

[0012] Additionally, or alternatively, the retractable jaw at the second end can securely grip the electrode before a rotational or torquing force is applied to the electrode though the opening in the thermal spray gun in order to remove or scat the electrode from or into the gun chamber.

[0013] In embodiments, an apparatus includes a longitudinal body having a first end and a second end. The first end includes a wrench, the second end includes an electrode puller, and the body contains a trigger mechanism that controls the electrode puller jaw.

[0014] According to embodiments, the electrode puller may include at least two articulating fingers, preferably four articulating fingers, and more preferably six articulating fingers.

[0015] In accordance with embodiments, the trigger mechanism may be spring loaded.

[0016] In embodiments, the trigger mechanism can be coupled movably with respect to the longitudinal body.

[0017] According to other embodiments, the electrode puller may be at least partially retractable into the longitudinal body.

[0018] In still other embodiments, the longitudinal body can have an orifice at the second end and the electrode puller can be at least partially retractable into the longitudinal body.

[0019] In accordance with other embodiments, the wrench may be one of a spanner wrench or a socket wrench. The wrench can include a plurality of dowel pins extending from the first end forming the spanner wrench, preferably four or five dowel pins. In other embodiments, the wrench may include a plurality of wrench flats extending from the first end to form a socket wrench.

[0020] According to still other embodiments, wherein the electrode puller can include a retractable member and a segmented collet extending from the second end.

[0021] In accordance with further embodiments, a cap may be configured to cover the wrench and at least part of the first end. [0022] In still other embodiments, the electrode puller may include an elongated arm located within the longitudinal body that is coupled to a collet comprising a plurality of segments. The longitudinal body can include two slots arranged diametrically opposite each other and the elongated arm has a through hole, and the trigger mechanism may be arranged to extend through the through hole and the two slots. The apparatus may further include a sleeve positionable over the longitudinal body, the sleeve having two holes diametrically opposite each other and the trigger mechanism is arranged to further extend through the holes in the sleeve.

[0023] In accordance with still yet other embodiments, a method of removing an electrode from a thermal spray gun with any of the above-described embodiments of the apparatus includes: inserting the wrench on the first end of the longitudinal body into a thermal spray gun to contact an electrode retaining nut; removing the electrode retaining nut from the thermal spray gun with the wrench; inserting the electrode puller on the second end of the longitudinal body into the thermal spray gun so the electrode puller surrounds the electrode; and pulling the trigger mechanism to firmly grasp the electrode and removing the electrode from the thermal spray gun.

[0024] Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

[0026] Fig. 1 shows the tools of the prior art, i.e., an electrode spanner wrench and an electrode puller pliers, for removing an electrode from a thermal spray gun;

[0027] Figs. 2A - 2D show various views and an exploded view of an embodiment of the electrode removal tool ;

[0028] Figs. 3A - 3D show various view and an exploded view of another embodiment of the electrode removal tool ; [0029] Fig. 4 shows the first end of the electrode removal tool depicted in Fig. 2 being inserted into the opening in a thermal spray gun through which the electrode is accessible;

[0030] Fig. 5 shows the first end of the electrode removal tool after removal of and/or prior to inserting a retaining nut from/into the opening the thermal spray gun depicted in Fig. 4;

[0031] Fig. 6 shows the second end of the electrode removal tool being inserted into the opening in the thermal spray gun;

[0032] Fig. 7 shows the trigger being actuated to retract the jaw at the second end of the electrode removal device when it is inserted into the opening in the thermal spraying device;

[0033] Fig. 8 shows the second end holding the electrode removed from the opening in the thermal spraying device; and

[0034] Fig. 9 shows an exemplary flow diagram of a process for removing an electrode from a thermal spray gun using the tools depicted in Figs. 2A - 2D and 3A - 3D.

DETAILED DESCRIPTION

[0035] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

[0036] Figs. 2A and 2B depict a side and top view of an embodiment of an electrode removal tool or device 20 in a fully assembled state, Fig. 2C depicts a cross-sectioned view of the top view the embodiments shown in Fig. 2B and Fig. 2D depicts electrode removal device 20 in exploded view. Electrode removal tool 20 includes a main body 21 having a first end 27 and a second end 28. One or more dowel pins 26 are arranged, e.g., via a press fit connection, on or at first end 27, as a wrench, e.g., spanner wrench for removing a retaining ring holding the electrode in an electrode chamber of the thermal spray gun, and a removable cap 23 is provided to cover first end 27 and dowel pins 26 when the retaining ring removal tool is not in use. In the illustrated embodiment, first end 27 may be provided with four dowel pins 26, but the number of dowel pins can vary depending upon the structure of the retaining ring to be removed or installed, or depending upon the diameter of dowel pins 26 and/or the amount of torque needed to remove/tighten the retaining ring. In alternate embodiments, the dowel pins can be replaced by wrench flats at the first end to form a socket-type wrench for removal of the retaining ring of some thermal spray gun designs.

[0037] A retractable member 22 is arranged at second end 28. A spring 24, e.g., a spring element formed from spring steel, such as a wave spring, surrounds an arm 29 of retractable member 22 to bias retractable member 22 outwardly from second end 28 and into a normally open or receiving position. At an end of retractable member 22, a collet or collet chuck 225 is provided for grasping the electrode. In the illustrated embodiment, collet or collet chuck 225, in contrast to clamshell design of known electrode puller pliers 12 shown in Fig. 1, can include plural segments, e.g., six segments, to provide plural points of contact for firmly grasping and holding the electrode for removal or installation. A dowel pin or trigger 25 is insertable through a slot 215 in main body 21 and through hole 291 in arm 29 to actuate retractable member 22. Via the tension in spring 24, trigger 25 is normally biased at a bottom, i.e., a second end side of slot 215. Moreover, slot 215 can be configured with an angled portion recessed below the surface of tool body 21 that extends from a stop preventing dowel pin or trigger 25 from movement via spring 24 to a bottom end of slot 215 to prevent finger pinching. By pulling trigger 25 along slot 215 toward the first end 27, the segments of collet or collet chuck 225 are pulled into an interior of main body 21, which results in the free ends of the segments to close like jaws onto the electrode until trigger 25 is released and spring 24 returns retractable member 22 to its normally open or receiving position.

[0038] Figs. 3A and 3B depict a side and top view of an embodiment of an electrode removal tool or device 30 in a fully assembled state, Fig. 3C depicts a cross-sectioned view of the top view the embodiments shown in Fig. 3B and Fig. 3D depicts electrode removal device 30 in exploded view. Electrode removal tool 30 includes a main body 31 having a first end 37 and a second end 38. One or more dowel pins 36 are arranged, e.g., via a press fit connection, on or at first end 37 as a wrench, e.g., spanner wrench for removing a retaining ring holding the electrode in the electrode chamber of the thermal spray gun, and a removable cap 33 is provided to cover first end 37 and dowel pins 36 when the retaining ring removal tool is not in use. O-rings 312 are also arranged over a neck portion at first end 37 to hold removable cap 33 on first end 37. In the illustrated embodiment, first end 37 may be provided with five dowel pins 36, but, as discussed above, the number of dowel pins can vary depending upon the structure of the retaining ring to be removed or installed, or depending upon the diameter of dowel pins 36 and/or the amount of torque needed to remove/tighten the retaining ring. As in the embodiments shown in Figs. 2A - 2D, it is understood that the dowel pins can be replaced by wrench flats at the first end to form a socket-type wrench for removal of the retaining ring of some thermal spray gun designs.

[0039] A retractable member 32 is arranged at second end 38. A spring 34, e.g., a spring element formed from spring steel, such as a wave spring, surrounds an arm 39 of retractable member 32 to bias retractable member 32 outwardly from second end 38 and into a normally open or receiving position. At an end of retractable member 32, a collet or collet chuck 325 is provided for grasping the electrode. In the illustrated embodiment, collet or collet chuck 325, in contrast to clamshell design of known electrode puller pliers 12 shown in Fig. 1, can include plural segments, e.g., six segments, to provide plural points of contact for firmly grasping and holding the electrode for removal or installation. A dowel pin or trigger 35 is insertable through a slot 315 in main body 31 and through hole 391 in arm 39 to actuate retractable member 32. However, before dowel pin or trigger 35 is inserted through slot 315 and opening 391, a sleeve 350 can be provided over tool body 31 for ease of use and avoiding finger pinches, so that dowel pin or trigger 35 inserted through hole 355 in sleeve 350, through slot 315 and opening 391 and out through the opposite end of body 31 and sleeve 350. Via the tension in spring 34, trigger 35 is normally biased at a bottom, i.c., a second end side of slot 315. By pulling trigger 35 along slot 315 toward the first end 37, the segments of collet or collet chuck 325 are pulled into an interior of main body 31, which results in the free ends of the segments to close like jaws onto the electrode until trigger 35 is released and spring 34 returns retractable member 32 to its normally open or receiving position.

[0040] As shown in Fig. 4, first end 37 of tool 20 and dowels 36 are configured as a spanner wrench, having a similar configuration to electrode spanner wrench 11 shown in Fig. 1, to be insertable into an opening 41 in a thermal spray gun. A retaining ring 51 (see Fig. 5), which is designed to retain or hold the electrode in the gun chamber of the thermal spray gun, is accessible through opening 41 in the thermal spray gun. The number of dowels 36 correspond to a number of receptacles in the retaining ring, which in the illustrated embodiment is four. As first end 37 is inserted into opening 41 in the thermal spray gun (see Fig. 5), dowel pins 36 (or spanner wrench) engage the receptacles 52 in retaining ring 51. After engagement, a rotational or unscrewing force can be applied to retaining ring 51 via the tool 20, so that the retaining ring 51 can be removed from the thermal spray gun through opening 41. Fig. 5 shows retaining ring 51 after removal from the thermal spray gun via opening 41. However, Fig. 5 can also be understood to show retaining ring 51 prior to insertion and seating via first end 37 and dowels 36 into the thermal spray gun through opening 41.

[0041] As shown in Fig. 6, second end 38 of tool 20 is configured to be insertable into an opening 41 and into an electrode chamber in the thermal spray gun. An electrode 81 (see Fig. 8) in the electrode chamber is accessible by collet or collet chuck 225 of retractable member 32 at second end 38 through opening 41 in the thermal spray gun. The second end 38 is inserted with the segments of collet or collet chuck 225 positioned in the normally open or receiving position until the segments of collet or collet chuck 225 surround electrode 81 seated in the electrode chamber, whereupon trigger 25 is pulled along slot 215, i.e., toward first end 27, to retract the segments of collet or collet chuck 225 in order to grasp electrode 81. Depending upon the manner in which the electrode is seated in the electrode chamber and with collet or collet chuck 225 still firmly grasping electrode 81, either a longitudinal or pulling force is applied to tool 20 and, therefore, electrode 81, to unseat electrode 81 from the electrode chamber and remove the electrode from the thermal spray gun via opening 41, or a rotational or screwing force is applied to tool 20 and, therefore, electrode 81, to unscrew the electrode from its seated position in the electrode chamber and remove electrode 81 from the thermal spray gun via opening 41. However, Fig. 8 can also be understood to show a new or replacement electrode 81 after placement into collet or collet chuck 225 and retraction of the segments via trigger 25 to hold new electrode 81 at second end 38 before inserting new electrode 81 into the electrode chamber via opening 41 and then applying the applicable longitudinal/pu shing force or rotational screwing force to seat new electrode 81 into the electrode chamber of the thermal spray gun through opening 41. [0042] In the embodiments of electrode removal tools 20 and 30 shown in Figs. 2 A - 2D and 3A - 3D, the segments of collet or collet chuck 225, 325, and preferably the entirety of retractable member 22, 32 can be made from a thermoplastic, such as polyoxymethylene (POM). In contrast to the known metal electrode pulling pliers 12 shown in Fig. 1, collet or collet chuck 225, 325 formed from a thermoplastic material will prevent scratching of the tungsten and copper electrode during removal from and/or installation into the thermal spray gun. Further, cap 23, 33 and tool body 21, 31 can be formed from thermoplastic or these parts may be formed from aluminum, e.g., aluminum 6061. Dowels 26, 36 (or, alternatively, wrench flats) and trigger 25, 26 can be made of steel, stainless steel or other suitable metals.

[0043] While the parts of tools 20, 30 may be manufactured by conventional processes (machining: milling & turning), collet or collet chuck 225, 325 and preferably all pails formed from thermoplastic, can be fabricated via 3D printing.

[0044] In a 3D printing process, such as Multi Jet Fusion technology, which builds in 80 micron layers, collet or collet chuck 225, 325 and other thermoplastic parts of tools 20, 30, can be formed from a thermoplastic material, such as a polyamide material (generally a powder), e.g., POM or PA 12 Black, as it is a self-supporting powder and needs no support structure and works equally well for fully functional prototypes or end-use pails. The POM or PA 12 material used by Multi Jet Fusion technology has a very fine grain, resulting in parts with higher density and lower porosity than parts produced with Laser Sintering. Of course, it is understood that other materials may also be used for 3D printing the thermoplastic pails without departing from the spirit and scope of the embodiments described herein.

[0045] Figure 9 shows an exemplary flow 90 for operating the electrode removal tool 20, 30 for removing an electrode from the electrode chamber of a thermal spray gun. In the exemplary process, cap 23, 33 is removed from first end 27, 37 to expose dowel pins 26, 36 of the electrode spanner wrench at 91. At 92, first end 27, 37 is inserted into the thermal spray gun, e.g., via opening 41, to gain access to electrode retaining nut 51, so that dowel pins 26, 36 are inserted into receptacles 52 so that electrode retaining nut 51 can be unscrewed and removed through opening 41. After removing electrode retaining nut 51, cap 23, 33 is placed back onto first end 27, 37 at 93. [0046] The user can rotate tool 20, 30 and insert second end 28, 38 into the thermal spray gun via opening 41 until the segments of collet or collet chuck 225, 325 surround the electrode in the electrode chamber at 94. Trigger 25, 35 can be pulled to retract the segments of collet or collet chuck 225, 325 to firmly grasp the electrode at 95. At 96, a longitudinal pulling force or a rotational/unscrewing torque can be applied on the electrode via tool 20, 30 to unseat the electrode from the electrode chamber and remove the electrode from the tool. Because the spring 24, 34 is preferably compressed while the segments of collet or collet chuck 225, 325 are retracted, releasing the tension on spring 24, 34 after the electrode has been removed from the thermal spray gun facilitates releasing of the electrode from tool 20, 30.

[0047] A new electrode can be inserted into the thermal spray gun by the reverse process shown in Fig. 9.

[0048] It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.