Consumable cartridge for a plasma arc cutting system

Patent metadata

Field	Value
Publication number	US-11278983-B2
Application number	US-201916677169-A
Country	US
Kind code	B2
Filing date	Nov 7, 2019
Priority date	Nov 13, 2013
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

A frame for a replaceable, unitary consumables cartridge configured for installation into a plasma arc torch. The frame includes a hollow body adapted to receive a translatable contact start electrode. The body has an internal surface and an external surface and includes: a substantially cylindrical metallic core; an electrically insulative overmolded plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core; and a set of flow passages fluidly connecting the external surface of the hollow body and the internal surface of the hollow body, the flow passages offset to impart a swirling fluid flow pattern to a plasma gases passing therethrough.

First claim

What is claimed is:

1. A frame for a replaceable, unitary consumables cartridge configured for installation into a plasma arc torch, the frame comprising:
a hollow body adapted to receive a translatable contact start electrode, the body having an internal surface and an external surface, the body including:
a substantially cylindrical metallic core;
an electrically insulative overmolded plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core, and
a set of flow passages fluidly connecting the external surface of the hollow body and the internal surface of the hollow body, the flow passages offset to impart a swirling fluid flow pattern to a plasma gases passing therethrough.

2. The frame of claim 1 wherein the substantially cylindrical metallic core is formed by stamping.

3. The frame of claim 1 wherein the substantially cylindrical metallic core is made of brass.

4. The frame of claim 1 wherein the substantially cylindrical metallic core includes an anodized portion.

5. The frame of claim 1 wherein each flow passage in the set of flow passages is radially offset from the other flow passages.

6. The frame of claim 1 wherein the flow passages have a total cross-sectional area of about one square inch.

7. The frame of claim 1 wherein a first end of the frame is configured to connect to a nozzle.

8. The frame of claim 7 wherein the set of flow passages extends into a further component inseparably attached to a front of the nozzle.

9. A method of cooling a plasma arc torch, the method comprising:
providing a composite consumable having a frame defining a plurality of holes, the composite consumable having integrated components including an electrode, a nozzle and a shield, the holes fluidly connecting an external surface of the frame and an internal surface of the frame, the holes offset to impart a swirling fluid flow pattern to plasma gases passing therethrough;
installing the composite consumable in the plasma arc torch; and
flowing a cooling fluid through the plurality of holes, the cooling fluid forming a fluid flow pattern that cools at least one of the electrode, nozzle or shield,
wherein the frame is adapted to receive a translatable contact start electrode and includes (i) a substantially cylindrical metallic core; and (ii) an electrically insulative overmolded plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core.

10. The method of claim 9 wherein the substantially cylindrical metallic core is formed by stamping.

11. The method of claim 9 wherein the substantially cylindrical metallic core is made of brass.

12. The method of claim 9 wherein the substantially cylindrical metallic core includes an anodized portion.

13. The method of claim 9 wherein each hole in the plurality of holes is radially offset from the other holes.

14. The method of claim 9 wherein the holes have a total cross-sectional area of about one square inch.

15. The method of claim 9 wherein a first end of the frame is configured to connect to a shield via a shield insulator, the shield thermally coupled to the frame.

16. A method of manufacturing a replaceable, unitary consumables cartridge configured for installation into a plasma arc torch, the method comprising:
providing a hollow body adapted to receive a translatable contact start electrode, the body having an internal surface and an external surface, the body including a substantially cylindrical metallic core;
overmolding an electrically insulative plastic casing on the hollow body, the electrically insulative plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core, and
providing a set of flow passages fluidly connecting the external surface of the hollow body and the internal surface of the hollow body, the flow passages offset to impart a swirling fluid flow pattern to a plasma gases passing therethrough.

Assignees

• Hypertherm Inc

Inventors

• Sanders Nicholas A
• Twarog Peter J
• Shipulski E Michael
• Zhang Yu

Classifications

• H05H1/3423

  Connecting means, e.g. electrical connecting means or fluid connections · CPC title

• B23K10/00 Primary

  Welding or cutting by means of a plasma · CPC title

• B23K10/006 Primary

  Control circuits therefor · CPC title

• H05H1/3489

  Means for contact starting · CPC title

• H05H1/3494

  Means for controlling discharge parameters · CPC title