Method of coating an emissive element
First Claim
1. A method of coating an emissive element for use in a plasma arc torch, the emissive element having an outer surface, the method comprising:
- heating the emissive element such that at least a portion of the outer surface of the emissive element becomes reactive;
applying a relatively non-emissive material to the heated and reactive outer surface of the emissive element;
allowing the relatively non-emissive material to melt against the outer surface of the emissive element; and
allowing the emissive element and relatively non-emissive material coated thereon to cool so that the relatively non-emissive material and the outer surface of the emissive element are securely bonded together.
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Accused Products
Abstract
An electrode for a plasma arc torch and method of fabricating the same are disclosed, wherein the electrode comprises a metallic holder defining a cavity in a forward end. An emissive element and separator assembly is positioned in the cavity. The emissive element has a layer of relatively non-emissive material on the outer surface thereof, which is preferably applied by heating the emissive element to a high temperature such that the emissive element becomes reactive, and spraying the relatively non-emissive material on the emissive element. The coated emissive element is positioned in the separator and the assembly is heated such that the relatively non-emissive material forms a strong bond between with the separator. The superior bonds between the emissive element and separator formed according to the present invention extend the life span of the electrode.
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Citations
22 Claims
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1. A method of coating an emissive element for use in a plasma arc torch, the emissive element having an outer surface, the method comprising:
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heating the emissive element such that at least a portion of the outer surface of the emissive element becomes reactive;
applying a relatively non-emissive material to the heated and reactive outer surface of the emissive element;
allowing the relatively non-emissive material to melt against the outer surface of the emissive element; and
allowing the emissive element and relatively non-emissive material coated thereon to cool so that the relatively non-emissive material and the outer surface of the emissive element are securely bonded together. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of forming an emissive element for use in a plasma arc torch, the emissive element having an outer surface, the method comprising:
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heating the emissive element to about 4000°
F. such that the outer surface of the emissive element becomes reactive;
spraying a relatively non-emissive material on the heated and reactive outer surface of the emissive element to form a layer having a thickness of at least 0.002 inches;
allowing the relatively non-emissive material to melt against the heated and reactive outer surface of the emissive element upon contact therewith; and
allowing the emissive element and relatively non-emissive material coated thereon to cool so that the relatively non-emissive material and the outer surface of the emissive element are securely bonded together. - View Dependent Claims (10)
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11. A method of forming an electrode for use in a plasma arc torch, the method comprising:
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heating an emissive element having an outer surface such that at least a portion of the outer surface of the emissive element becomes reactive;
applying a relatively non-emissive material to the heated and reactive outer surface of the emissive element;
allowing the relatively non-emissive material to melt against the outer surface of the emissive element and be securely bonded thereto;
positioning the emissive element in a cavity defined by a relatively non-emissive separator such that the cavity is substantially filled by the emissive element; and
bonding the emissive element to the relatively non-emissive separator. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification