Forward flow, high access consumables for a plasma arc cutting torch

• US 8,981,253 B2
• Filed: 09/09/2011
• Issued: 03/17/2015
• Est. Priority Date: 09/13/2006
• Status: Active Grant

• Current Assignee: Hypertherm Incorporated
• Original Assignee: Hypertherm Incorporated
• Inventors: Shipulski, E. Michael, Sanders, Nicholas A., Jason, Jay L., Mather, Jonathan, Twarog, Peter J.
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US13/229,105
• Publication Number:
  US 20120055906A1
• Time in Patent Office: 1,285 Days
• Field of Search: 219/121.39, 219/121.5, 219/121.51, 219/121.48, 219/121.49, 219/75, 313/231.41, 315/111.21
• US Class Current: 219/121.53
• CPC Class Codes: B23K 10/00 Welding or cutting by means of a plasma
• CPC Class Codes: H05H 1/34 Details, e.g. electrodes, nozzles
• CPC Class Codes: H05H 1/3442 Cathodes with inserted tip
• CPC Class Codes: H05H 1/3457 Nozzle protection devices
• CPC Class Codes: H05H 1/3478 Geometrical details
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A nozzle for a plasma arc cutting torch includes a substantially hollow, elongated body capable of receiving an electrode. The nozzle body defines a longitudinal axis and has a length along the axis from a first end of the nozzle body to a second end of the nozzle body. The nozzle also includes a plasma exit orifice disposed at the first end of the body. The first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3.

Claims

1. A nozzle for a plasma arc cutting torch, the nozzle comprising:

a substantially hollow, elongated body capable of receiving an electrode, the body defining a longitudinal axis and having a length and a width, the length of the body extending along the axis from a first end of the body to a second end of the body and the width of the body being width of widest portion of the nozzle body that extends along the longitudinal axis between the first end of the body and the second end of the body, wherein a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3; and

a plasma exit orifice disposed at the first end of the body.

2. The nozzle of claim 1 further comprising:

an end face at the first end of the body through which the plasma exit orifice is disposed; and

at least one supplemental orifice disposed through the end face relative to the plasma exit orifice.

3. The nozzle of claim 2 wherein the at least one supplemental orifice is canted.

4. The nozzle of claim 2 wherein a majority of a cooling gas that cools the nozzle exits through the at least one supplemental orifice.

5. The nozzle of claim 2 further comprising at least one orifice disposed through the body of the nozzle.

6. The nozzle of claim 1 further comprising at least one orifice disposed through the body of the nozzle.

7. The nozzle of claim 6 wherein the at least one orifice is canted.

8. The nozzle of claim 6 wherein a majority of a cooling gas that cools the nozzle exits through the at least one orifice.

9. The nozzle of claim 1 further comprising at least one heat exchanging element disposed on the nozzle body and in thermal communication with a cooling gas.

10. The nozzle of claim 9 wherein the at least one heat exchanging element is disposed on an outer surface of the nozzle body.

11. The nozzle of claim 9 wherein the at least one heat exchanging element is disposed on an inner surface of the nozzle body.

12. The nozzle of claim 1 wherein the length is greater than about 2 inches.

13. The nozzle of claim 1 wherein the length is greater than about 4 inches.

14. The nozzle of claim 1 wherein the length is greater than about 6 inches.

15. The nozzle of claim 1 wherein the length is greater than about 8 inches.

16. The nozzle of claim 1 wherein the length is greater than about 10 inches.

17. The nozzle of claim 1 wherein the ratio of the length to the width is greater than about 4.

18. The nozzle of claim 1 wherein the ratio of the length to the width is greater than about 5.

19. The nozzle of claim 1 wherein the ratio of the length to the width is greater than about 7.

20. The nozzle of claim 1 wherein the ratio of the length to the width is greater than about 9.

21. The nozzle of claim 1 wherein the ratio of the length to the width is greater than about 11.

22. The nozzle of claim 1 wherein the plasma arc torch is gas cooled.

23. A plasma arc torch comprising the nozzle of claim 1.

24. A method of cutting a workpiece comprising:

providing a plasma arc torch having a body which includes a flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;

providing the nozzle of claim 1 mounted relative to an electrode at a distal end of the torch body to define the plasma chamber;

wherein at least one supplemental orifice is disposed through at least one of an end face or a side wall of the nozzle, the at least one supplemental orifice being relative to the plasma exit orifice;

operating the plasma arc cutting torch at an amperage level of at least about 15 Amps; and

flowing a majority of a cooling gas that cools the nozzle through the at least one supplemental orifice at the distal end of the torch body.

45. A torch tip for a handheld plasma torch, the handheld plasma torch having a trigger and a torch tip mount, the torch tip comprising:

the nozzle of claim 1;

an electrode disposed relative to the nozzle; and

a housing disposed relative to the nozzle and the electrode, the nozzle, electrode and housing forming an assembled torch tip having a distal end and a proximal end, the proximal end of the assembled torch tip configured to couple to the torch tip mount,

wherein a distance from the distal end to the proximal end of the assembled torch tip is greater than about 3 inches.

46. The torch tip of claim 45 wherein the nozzle is elongated.

47. The torch tip of claim 46 wherein the nozzle has a length along a longitudinal axis extending from a first end of the nozzle and a second end of the nozzle, the length from the first end to the second end of the nozzle greater than about 2 inches.

48. The torch tip of claim 45 wherein the electrode is elongated.

49. The torch tip of claim 45 wherein the housing comprises an adapter capable of extending the distance from the distal end to the proximal end of the assembled torch tip.

50. The torch tip of claim 45 wherein the distance from the distal end to the proximal end of the assembled torch tip is greater than about 5 inches.

51. The torch tip of claim 45 wherein the distance from the distal end to the proximal end of the assembled torch tip is greater than about 7 inches.

52. The torch tip of claim 45 wherein the distance from the distal end to the proximal end of the assembled torch tip is greater than about 9 inches.

53. The torch tip of claim 45 wherein the distance from the distal end to the proximal end of the assembled torch tip is greater than about 11 inches.

54. The torch tip of claim 45 further comprising at least one heat exchanging element disposed on the nozzle and in thermal communication with a cooling gas.

55. The torch tip of claim 54 wherein the at least one heat exchanging element is disposed on an outer surface of the nozzle.

56. The torch tip of claim 55 wherein the at least one heat exchanging element is disposed on an inner surface of the nozzle.

57. A torch tip for a handheld plasma torch, the handheld plasma torch having a trigger and a torch tip mount, the torch tip comprising:

the nozzle of claim 1;

an electrode disposed relative to the nozzle; and

a housing disposed relative to the nozzle and the electrode, the nozzle, electrode and housing forming an assembled torch tip having a distal end and a proximal end, the proximal end of the assembled torch tip configured to couple to the torch tip mount, the assembled torch tip defining a longitudinal axis and having a length along the axis from the proximal end to the distal end,

wherein a ratio of the length of the assembled torch tip to a width of the assembled torch tip is greater than about 3.

59. A method for extending the life of a plasma arc torch, the method comprising:

providing a torch body which includes a plasma gas flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;

providing the nozzle of claim 1 mounted relative to an electrode at a distal end of the torch body to define the plasma chamber,

wherein the length of the nozzle body from the first end to the second end is greater than about 2 inches; and

wherein the nozzle comprises at least one supplemental orifice disposed through at least one of an end face or a side wall of the nozzle, the at least one supplemental orifice relative to the plasma exit orifice;

operating the plasma arc torch at an amperage level of at least about 15 Amps; and

flowing a majority of a cooling gas that cools the nozzle through the at least one gas outlet.

60. A method for extending the life of a plasma arc torch, the method comprising:

providing a torch body which includes a plasma gas flow path for directing a plasma gas through a swirl ring to a plasma chamber in which a plasma arc is formed;

providing the nozzle of claim 1 mounted relative to an electrode at a distal end of the torch body to define the plasma chamber,

wherein the length of the nozzle body from the first end to the second end is greater than about 2 inches;

operating the plasma arc torch at an amperage level of at least about 15 Amps; and

flowing a majority of a cooling gas that cools the nozzle out the distal end of the torch body.

25. A nozzle assembly for a plasma arc cutting torch, the nozzle assembly comprising:

a substantially hollow, elongated body defining a longitudinal axis and having a length along the axis from a first end of the body to a second end of the body;

a plasma exit orifice disposed at the first end of the body; and

a structure configured to translatably receive a plasma arc cutting torch electrode, the structure being integrally formed with the nozzle body and comprising a body with canted gas ports to provide a swirling plasma gas during operation of the plasma arc cutting torch.

26. The nozzle assembly of claim 25 wherein the length is greater than about 2 inches.

27. The nozzle assembly of claim 25 wherein the length is greater than about 4 inches.

28. The nozzle assembly of claim 25 wherein the length is greater than about 6 inches.

29. The nozzle assembly of claim 25 further comprising:

an end face at the first end of the body through which the plasma exit orifice is disposed; and

at least one supplemental orifice disposed through at least one of the end face or a side wall relative to the plasma exit orifice.

30. The nozzle assembly of claim 29 wherein the at least one supplemental orifice is canted.

31. The nozzle assembly of claim 29 wherein a majority of a cooling gas that cools the nozzle exits through the at least one supplemental orifice.

32. The nozzle assembly of claim 25 further comprising at least one heat exchanging element disposed on the nozzle body and in thermal communication with a cooling gas.

33. The nozzle assembly of claim 32 wherein the at least one heat exchanging element is disposed on an outer surface of the nozzle body.

34. The nozzle assembly of claim 32 wherein the at least one heat exchanging element is disposed on an inner surface of the nozzle body.

35. A plasma arc torch comprising the nozzle assembly of claim 25.

36. A method of cutting a workpiece comprising:

providing the nozzle assembly of claim 25 mounted relative to an electrode at a distal end of a torch body to define a plasma chamber,

wherein at least one supplemental orifice is disposed through an end face of the nozzle assembly relative to the plasma exit orifice;

operating the plasma arc cutting torch at an amperage level of at least about 15 Amps; and

flowing a majority of a cooling gas that cools the nozzle through the at least one supplemental orifice.

37. The method of claim 36 wherein the nozzle assembly further comprises at least one orifice disposed through the nozzle body.

58. A method of aligning an electrode in a plasma arc torch, the method comprising:

providing the nozzle assembly of claim 25;

disposing an elongated electrode within the body of the nozzle, the electrode having a first end and a second end, the electrode body defining a bore in the first end of the electrode for receiving an insert; and

aligning the bore of the electrode with the plasma exit orifice of the nozzle via the structure.

38. An electrode for a high visibility plasma arc cutting torch comprising:

an elongated electrode body having a first end and a second end, the body defining a bore in the first end for receiving an insert, the electrode body including;

(i) a first body portion extending from the first end;

(ii) a second body portion extending to the second end; and

(iii) a heat transfer zone located relative to the first body portion at the first end of the electrode body,

wherein during operation of the plasma torch at a current greater than about 15 Amps, the heat transfer zone is in thermal communication with a cooling gas and is configured such that a majority of heat generated during the operation of the plasma torch is removed from the heat transfer zone.

39. The electrode of claim 38 wherein the heat transfer zone is greater than about 1 square inch.

40. The electrode of claim 38 wherein the heat transfer zone is between about 1 square inch and about 3 square inches.

41. A plasma arc torch comprising the electrode of claim 38.

42. An electrode for a high visibility plasma arc cutting torch comprising:

an elongated electrode body having a first end and a second end, the body defining a bore in the first end for receiving an insert, the electrode body including;

(i) a first body portion extending from the first end;

(ii) a second body portion extending to the second end; and

(iii) a heat transfer zone located relative to the first body portion at the first end of the electrode body,

wherein the heat transfer zone is greater than about 1 square inch.

43. The electrode of claim 42 wherein the heat transfer zone is between about 1 square inch and 3 square inches.

44. A plasma arc torch comprising the electrode of claim 42.