Tip gas distributor

• US 20020185475A1
• Filed: 02/26/2002
• Published: 12/12/2002
• Est. Priority Date: 02/27/2001
• Status: Active Grant

• Current Assignee: Victor Equipment Co. (Enovis Corp.)
• Original Assignee: Thermal Dynamics Corporation (Enovis Corp.)
• Inventors: Hewett, Roger W., Jones, Joseph P., Chen, Shiyu, Horner-Richardson, Kevin D.
• Granted Patent: US 6,774,336 B2
• Time in Patent Office: Days
• US Class Current: 219/121.36
• CPC Class Codes: H05H 1/34 Details, e.g. electrodes, nozzles
• CPC Class Codes: H05H 1/3468 Vortex generators
• CPC Class Codes: H05H 1/3489 Means for contact starting

Abstract

A tip gas distributor is provided that preferably comprises a plurality of swirl holes and a plurality of secondary gas holes, wherein the swirl holes direct a plasma gas to generate a plasma stream, and the secondary gas holes direct a secondary gas to stabilize the plasma stream. Additionally, a tip gas distributor is provided that comprises swirl passages and secondary gas passages formed between the tip gas distributor and an adjacent component to generate and stabilize the plasma stream. Further, methods of generating and stabilizing the plasma stream are provided through the use of the swirl holes and passages, along with the secondary gas holes and passages.

Claims

1. A tip gas distributor comprising:

a plurality of swirl holes; and

a plurality of secondary gas holes,

wherein the swirl holes direct a plasma gas to generate a plasma stream, and the secondary gas holes direct a secondary gas to stabilize the plasma stream.

2. The tip gas distributor according to claim 1 further comprising:

an annular flange formed at a proximal end of the tip gas distributor;

a generally cylindrical distal portion formed at a distal end of the tip gas distributor;

a primary gas passage formed within the generally cylindrical distal portion; and

a central exit orifice,

wherein the swirl holes and the secondary gas holes are formed through the annular flange such that the swirl holes direct the primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice, and the secondary gas holes direct a secondary gas along the generally cylindrical distal portion to stabilize the plasma stream exiting the central exit orifice.

3. The tip gas distributor according to claim 2, wherein the swirl holes are offset from a center of the tip gas distributor.

4. The tip gas distributor according to claim 2, wherein the secondary gas holes are oriented approximately normal through the annular flange.

5. The tip gas distributor according to claim 2, wherein the annular flange further defines a distal face, and the tip gas distributor further comprises an annular recess formed on the distal face such that the secondary gas holes formed through the annular flange are in fluid communication with the annular recess.

6. The tip gas distributor according to claim 2 further comprising a conical interior surface formed at a proximal end of the tip gas distributor, the swirl holes being formed through the conical interior surface and the annular flange.

7. A tip gas distributor defining a proximal end and a distal end, the tip gas distributor comprising:

an annular flange formed at the proximal end;

a generally cylindrical distal portion formed at the distal end;

a primary gas passage formed within the generally cylindrical distal portion;

a central exit orifice;

a plurality of swirl holes formed through the annular flange; and

a plurality of secondary gas holes formed through the annular flange,

wherein the swirl holes direct a primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice, and the secondary gas holes direct a secondary gas along the generally cylindrical distal portion to stabilize the plasma stream exiting the central exit orifice.

8. The tip gas distributor according to claim 7, wherein the swirl holes are offset from a center of the tip gas distributor.

9. The tip gas distributor according to claim 7, wherein the secondary gas holes are oriented approximately normal through the annular flange.

10. The tip gas distributor according to claim 7, wherein the annular flange further defines a distal face, and the tip gas distributor further comprises an annular recess formed on the distal face such that the secondary gas holes formed through the annular flange are in fluid communication with the annular recess.

11. The tip gas distributor according to claim 7 further comprising a conical interior surface formed at the proximal end of the tip gas distributor, the swirl holes being formed through the conical interior surface and the annular flange.

13. The tip gas distributor according to claim 12, wherein the swirl holes are oriented at an angle through the annular flange.

14. The tip gas distributor according to claim 12, wherein the secondary gas holes are oriented approximately normal through the annular flange.

15. The tip gas distributor according to claim 12 further comprising a conical interior surface formed at the proximal end of the tip gas distributor, the swirl holes being formed through the conical interior surface and the annular flange.

17. The tip gas distributor according to claim 16 further comprising:

an annular flange formed at a proximal end of the tip gas distributor;

a generally cylindrical distal portion formed at a distal end of the tip gas distributor;

a primary gas passage formed within the generally cylindrical distal portion; and

a central exit orifice,

wherein the swirl holes are formed through the annular flange such that the swirl holes direct the primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice.

18. The tip gas distributor according to claim 17 further comprising a conical interior surface formed at a proximal end of the tip gas distributor, the swirl holes being formed through the conical interior surface and the annular flange.

19. The tip gas distributor according to claim 16, wherein the swirl holes are offset from a center of the tip gas distributor.

12. A tip gas distributor defining a proximal end and a distal end, the tip gas distributor comprising:

an annular flange formed at the proximal end, the annular flange defining a distal face;

an annular recess formed on the distal face;

a generally cylindrical distal portion formed at the distal end;

a primary gas passage formed through the generally cylindrical distal portion;

a central exit orifice;

a plurality of swirl holes formed through the annular flange and in fluid communication with the primary gas passage and the central exit orifice; and

a plurality of secondary gas holes formed through the annular flange and in fluid communication with the annular recess,

wherein the swirl holes direct a primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice, and the secondary gas holes direct a secondary gas along the generally cylindrical distal portion to stabilize the plasma stream exiting the central exit orifice.

16. A tip gas distributor comprising:

a plurality of swirl holes,

wherein the swirl holes direct a plasma gas to generate a plasma stream.

20. A tip gas distributor comprising:

at least one swirl passage; and

at least one secondary gas passage,

wherein the swirl passage directs a plasma gas to generate a plasma stream, and the secondary gas passage directs a secondary gas to stabilize the plasma stream.

21. The tip gas distributor according to claim 20 further comprising:

an annular flange; and

a proximal face formed on the annular flange,

wherein the swirl passage is formed on the proximal face of the annular flange.

22. The tip gas distributor according to claim 20 further comprising a distal face,

wherein the secondary gas passage is formed on the distal face of the annular flange.

24. The tip gas distributor according to claim 23 further comprising:

an annular flange; and

a proximal face formed on the annular flange,

wherein the swirl passage is formed on the proximal face of the annular flange.

27. The tip gas distributor according to claim 26 further comprising:

an annular flange formed at a proximal end of the tip gas distributor;

a generally cylindrical distal portion formed at a distal end of the tip gas distributor;

a primary gas passage formed within the generally cylindrical distal portion; and

a central exit orifice,

wherein the swirl hole and the secondary gas hole are formed through the annular flange such that the swirl hole directs the primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice, and the secondary gas hole directs a secondary gas along the generally cylindrical distal portion to stabilize the plasma stream exiting the central exit orifice.

28. The tip gas distributor according to claim 27, wherein the swirl hole is offset from a center of the tip gas distributor.

29. The tip gas distributor according to claim 27, wherein the secondary gas hole is oriented approximately normal through the annular flange.

30. The tip gas distributor according to claim 27, wherein the annular flange further defines a distal face, and the tip gas distributor further comprises an annular recess formed on the distal face such that the secondary gas hole formed through the annular flange is in fluid communication with the annular recess.

31. The tip gas distributor according to claim 27 further comprising a conical interior surface formed at a proximal end of the tip gas distributor, the swirl hole being formed through the conical interior surface and the annular flange.

32. The tip gas distributor according to claim 26 further comprising three swirl holes and three secondary gas holes.

23. A tip gas distributor comprising:

at least one swirl passage,

wherein the swirl passage directs a plasma gas to generate a plasma stream.

25. A tip gas distributor comprising:

an annular flange;

a distal face formed on the annular flange; and

at least one secondary gas passage formed on the distal face,

wherein the secondary gas passage directs a secondary gas to stabilize the plasma stream.

26. A tip gas distributor comprising:

at least one swirl hole; and

at least one secondary gas hole,

wherein the swirl hole directs a plasma gas to generate a plasma stream, and the secondary gas hole directs a secondary gas to stabilize the plasma stream.

33. A tip gas distributor comprising:

at least one swirl hole,

wherein the swirl hole directs a plasma gas to generate a plasma stream.

34. The tip gas distributor according to claim 33 further comprising:

an annular flange formed at a proximal end of the tip gas distributor;

a generally cylindrical distal portion formed at a distal end of the tip gas distributor;

a primary gas passage formed within the generally cylindrical distal portion; and

a central exit orifice,

wherein the swirl hole is formed through the annular flange such that the swirl hole directs the primary gas to generate a plasma stream that flows through the primary gas passage and the central exit orifice.

35. The tip gas distributor according to claim 34 further comprising a conical interior surface formed at a proximal end of the tip gas distributor, the swirl hole being formed through the conical interior surface and the annular flange.

36. The tip gas distributor according to claim 33, wherein the swirl hole is offset from a center of the tip gas distributor.

37. The tip gas distributor according to claim 33 further comprising three swirl holes.

39. The tip gas distributor according to claim 38 further comprising:

an annular flange;

a distal face formed on the annular flange; and

annular recess formed on the distal face,

wherein the secondary gas holes are formed through the annular flange and are in fluid communication with the annular recess.

40. The tip gas distributor according to claim 39 further comprising:

a generally cylindrical distal portion,

wherein the secondary gas flows along the generally cylindrical distal portion to stabilize the plasma stream.

41. The tip gas distributor according to claim 39, wherein the secondary gas holes are formed approximately normal through the annular flange.

38. A tip gas distributor comprising:

a plurality of secondary gas holes,

wherein the secondary gas holes direct a secondary gas to stabilize a plasma stream.

42. A tip gas distributor comprising:

at least one secondary gas hole,

wherein the secondary gas hole directs a secondary gas to stabilize a plasma stream.

43. The tip gas distributor according to claim 42 further comprising:

an annular flange;

a distal face formed on the annular flange; and

annular recess formed on the distal face,

wherein the secondary gas hole is formed through the annular flange and is in fluid communication with the annular recess.

44. The tip gas distributor according to claim 43 further comprising:

a generally cylindrical distal portion,

wherein the secondary gas flows from the annular recess along the generally cylindrical distal portion to stabilize the plasma stream.

45. The tip gas distributor according to claim 43, wherein the secondary gas hole is formed approximately normal through the annular flange.

46. The tip gas distributor according to claim 42 comprising three secondary gas holes.

48. The method according to claim 47 further comprising the step of directing the plasma gas through the swirl holes and into a primary gas passage.

49. The method according to claim 47 further comprising the steps of:

directing the secondary gas through the secondary gas holes and into an annular recess; and

directing the secondary gas along a generally cylindrical portion of the tip gas distributor.

50. The method according to claim 47 further comprising the step of metering a flow rate through a central exit orifice and the secondary gas holes for an operating current level.

51. The method according to claim 47 further comprising the step of changing a number and size of the secondary gas holes and a size of a central exit orifice for an operating current level.

47. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream and directing a secondary gas to stabilize the plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas and the secondary gas;

directing the plasma gas through a plurality of swirl holes formed in a tip gas distributor of the plasma arc apparatus; and

directing the secondary gas through a plurality of secondary gas holes formed in the tip gas distributor,

wherein the swirl holes direct the plasma gas to generate the plasma stream and the secondary gas holes direct the secondary gas to stabilize the plasma stream exiting the tip gas distributor.

52. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas;

directing the plasma gas through a plurality of swirl holes formed in a tip gas distributor of the plasma arc apparatus,

wherein the swirl holes direct the plasma gas to generate the plasma stream.

53. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream and directing a secondary gas to stabilize the plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas and the secondary gas;

directing the plasma gas through at least one swirl hole formed in a tip gas distributor of the plasma arc apparatus; and

directing the secondary gas through at least one secondary gas hole formed in the tip gas distributor,

wherein the swirl hole directs the plasma gas to generate the plasma stream and the secondary gas hole directs the secondary gas to stabilize the plasma stream exiting the tip gas distributor.

54. The method according to claim 53 further comprising the step of directing the plasma gas through the swirl hole and into a primary gas passage.

55. The method according to claim 53 further comprising the steps of:

directing the secondary gas through the secondary gas hole and into an annular recess; and

directing the secondary gas from the annular recess along a generally cylindrical portion of the tip gas distributor.

58. The method according to claim 57 further comprising the steps of:

directing the secondary gas through the secondary gas holes and into an annular recess; and

directing the secondary gas from the annular recess along a generally cylindrical portion of the tip gas distributor.

56. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas;

directing the plasma gas through at least one swirl hole formed in a tip gas distributor of the plasma arc apparatus,

wherein the swirl hole directs the plasma gas to generate the plasma stream.

57. In a plasma arc apparatus, a method of directing a secondary gas to stabilize a plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the secondary gas; and

directing the secondary gas through a plurality of secondary gas holes formed in a tip gas distributor,

wherein the secondary gas holes direct the secondary gas to stabilize the plasma stream exiting the tip gas distributor.

59. In a plasma arc apparatus, a method of directing a secondary gas to stabilize a plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the secondary gas; and

directing the secondary gas through at least one secondary gas hole formed in a tip gas distributor,

wherein the secondary gas hole directs the secondary gas to stabilize the plasma stream exiting the tip gas distributor.

60. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream and directing a secondary gas to stabilize the plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas and the secondary gas;

directing the plasma gas through at least one swirl passage formed in a tip gas distributor of the plasma arc apparatus; and

directing the secondary gas through at least one secondary gas passage formed in the tip gas distributor,

wherein the swirl passage directs the plasma gas to generate the plasma stream and the secondary gas passage directs the secondary gas to stabilize the plasma stream exiting the tip gas distributor.

61. In a plasma arc apparatus, a method of directing a plasma gas to generate a plasma stream, the method comprising the steps of:

providing a source of gas;

distributing the gas through the plasma arc apparatus to generate the plasma gas; and

directing the plasma gas through at least one swirl passage formed in a tip gas distributor of the plasma arc apparatus,

wherein the swirl passage directs the plasma gas to generate the plasma stream.