Asymmetric consumables for a plasma arc torch

Patent metadata

Field	Value
Publication number	US-10721812-B2
Application number	US-201715685659-A
Country	US
Kind code	B2
Filing date	Aug 24, 2017
Priority date	Aug 6, 2012
Publication date	Jul 21, 2020
Grant date	Jul 21, 2020

Abstract

A consumable set for a plasma arc torch is provided. The consumable set comprises a consumable tip including a plurality of consumable components, at least one of which includes an asymmetric feature asymmetrically disposed in the consumable tip relative to a longitudinal axis. The consumable set also includes a mounting element for coupling the consumable tip to a torch body. The mounting element is configured to axially secure the consumable tip relative to the torch body while permitting independent rotation of the consumable tip relative to the longitudinal axis during assembly. The mounting element is also configured to both axially and radially fix the consumable tip with respect to the torch body such that the asymmetric feature is locked at the specific radial orientation relative to the longitudinal axis after securement.

First claim

What is claimed is:

1. A consumable set for a plasma arc torch configured to generate a plasma arc, the plasma arc torch and the consumable set defining a central longitudinal axis extending therethrough, the consumable set comprising:
a consumable tip configured to direct a plasma arc to a workpiece, the consumable tip alignable along the central longitudinal axis and comprising a plurality of consumable components, at least one of the plurality of consumable components includes an asymmetric feature asymmetrically disposed in the consumable tip relative to the central longitudinal axis, the asymmetric feature of the consumable component defines at least one of (i) an axis of the consumable component that is oriented at a non-zero angle relative to the central longitudinal axis, (ii) an axis of the consumable component that is offset from the central longitudinal axis or (iii) an asymmetric cross section of the consumable component about the central longitudinal axis; and
a mounting element, comprising an inner retaining cap and an outer retaining cap, for coupling the consumable tip to a torch body, the mounting element configured to (i) axially secure the consumable tip relative to the torch body between the inner and outer retaining caps while permitting independent rotation of the consumable tip relative to the central longitudinal axis during assembly, the independent rotation permits positioning of the consumable tip at a specific radial orientation relative to the central longitudinal axis, and (ii) both axially and radially fix the consumable tip with respect to the torch body by at least one of the inner or outer retaining cap such that the asymmetric feature is locked at the specific radial orientation relative to the central longitudinal axis after securement while permitting the plasma arc to pass through the consumable components of the consumable tip.

2. The consumable set of claim 1 , wherein the plurality of consumable components of the consumable tip comprises a nozzle and a shield.

3. The consumable set of claim 2 , wherein the consumable tip further comprises a locking element configured to radially affix at least two of the plurality of consumable components with respect to each other.

4. The consumable set of claim 3 , wherein the plurality of consumable components and the locking element include complementary features configured to inter-fit with one another to orient the asymmetric feature.

5. The consumable set of claim 4 , wherein the complementary features comprise a flat surface disposed on a circumferential section of each of the consumable components and the locking element.

6. The consumable set of claim 3 , wherein each of the plurality of consumable components comprises an asymmetric feature asymmetrically disposed relative to the longitudinal axis, and the locking element maintains radial and axial alignment among the asymmetric features.

7. The consumable set of claim 3 , wherein the nozzle comprises an asymmetric nozzle exit orifice and the shield comprises an asymmetric shield exit orifice, and the locking element is configured to maintain radial and axial alignment between the nozzle exit orifice and the shield exit orifice.

8. The consumable set of claim 1 , further comprising:
a consumable body comprising at least an electrode; and
a plasma processing interface coupled to the torch body,
wherein the mounting element is configured to retain the consumable body and the consumable tip to the torch body via fixed engagement with the plasma processing interface to achieve the securement.

9. The consumable set of claim 8 , further comprising an ejector feature, connected to the mounting element, configured to disconnect the consumable body and the consumable tip from the plasma processing interface.

10. The consumable set of claim 8 , wherein the mounting element comprises a proximal end configured to fixedly engage the plasma processing interface after securement.

11. The consumable set of claim 8 , wherein the mounting element is at least one of rotatable or translatable relative to the torch body and the consumable tip during assembly prior to the fixed engagement with the plasma processing interface.

12. The consumable set of claim 10 , wherein the fixed engagement of the mounting element with the plasma processing interface at the proximal end causes the mounting element to impart a frictional force on the consumable tip at a distal end of the mounting element, thereby causing the mounting element to fixedly engage the consumable tip at the distal end, such that the asymmetric feature of the consumable tip is locked at the specific radial orientation relative to the longitudinal axis after securement.

13. The consumable set of claim 10 , wherein the fixed engagement of the mounting element with the plasma processing interface at the proximal end locks the consumable body in a specific radial orientation relative to the longitudinal axis.

14. A method for assembling the consumable set of the plasma arc torch of claim 1 , the method comprising:
loosely engaging a proximal end of the mounting element to the torch body, wherein a distal end of the mounting element axially secures the consumable tip while permitting independent rotation of the consumable tip relative to the mounting element;
orienting the consumable tip relative to the mounting element about the longitudinal axis to achieve the specific radial orientation of the asymmetric feature with respect to the longitudinal axis; and
fixedly engaging the mounting element to the torch body, wherein the fixed engagement imparts a frictional force between the mounting element and the consumable tip to both axially and radially secure the consumable tip to the torch body, such that the asymmetric feature of the torch tip is locked at the specific radial orientation relative to the longitudinal axis of the plasma arc torch after the fixed engagement.

15. The method of claim 14 , further comprising assembling the consumable tip having the plurality of consumable components by fixedly locking the plurality of consumable components to each other.

16. The method of claim 15 , further comprising connecting the consumable tip to the mounting element, such that the mounting element axially secures the consumable tip while permitting independent rotation of the consumable tip relative to the mounting element prior to the fixed engagement.

17. The method of claim 14 , wherein the plurality of consumable components of the consumable tip comprises a nozzle and a shield.

18. The method of claim 15 , wherein assembling the consumable tip further comprises aligning and inter-fitting one or more complementary features of the plurality of consumable components with one another to orient the asymmetric feature.

19. The method of claim 14 , wherein the fixed engagement of the mounting element to the torch body retains a consumable body and the consumable tip to the torch body.

20. The method of claim 19 , further comprising locking the consumable body to the torch body in a specific radial orientation relative to the longitudinal axis of the plasma arc torch upon fixedly engaging the mounting element to the torch body.

21. The method of claim 14 , further comprising rotating or translating the mounting element relative to the consumable tip or the torch body prior to the fixed engagement of the mounting body to the torch body.

Assignees

• Hypertherm Inc

Inventors

• Twarog Peter
• Darrow Clifford G
• Shipulski E Michael
• Higgens Martin

Classifications

• B23K10/00 Primary

  Welding or cutting by means of a plasma · CPC title

• H05H1/34 Primary

  Details, e.g. electrodes, nozzles · CPC title

• Y10T29/49778

  with aligning, guiding, or instruction · CPC title

• H05H1/3463

  Oblique nozzles · CPC title

• H05H2001/3463

  Electricity · mapped topic