Composite consumables for a plasma arc torch
First Claim
1. An electrode for use in a plasma arc torch, the electrode comprising:
- an elongated forward portion, defining a proximal end and a distal end, configured to provide an electrically conductive path from the distal end to the proximal end, the forward portion comprising a first conductive material;
a ring-shaped aft portion, defining a hollow center, configured to substantially surround a portion of the forward portion when the forward portion is located inside of the hollow center, wherein (1) the aft portion includes a pneumatic reaction region disposed on a radially-extensive segment of the aft portion for receiving a biasing flow of a pressurized gas and separating the electrode from a nozzle during pilot arc initiation (2) the aft portion comprises a second material that is different from the first material; and
an emitter disposed in the proximal end of the forward portion.
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Accused Products
Abstract
An electrode is provided for use in a plasma arc torch. The electrode includes a body having an elongated forward portion and a ring-shaped aft portion. The forward portion is configured to provide an electrically conductive path from the distal end to the proximal end. The forward portion comprises a first conductive material. The ring-shaped aft portion, defining a hollow center, is configured to substantially surround a portion of the forward portion when the forward portion is located inside of the hollow center. The aft portion includes a pneumatic reaction region for receiving a biasing flow of a pressurized gas. The aft portion comprises a second material. In some embodiments, the first conductive material is the same as the second material.
130 Citations
17 Claims
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1. An electrode for use in a plasma arc torch, the electrode comprising:
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an elongated forward portion, defining a proximal end and a distal end, configured to provide an electrically conductive path from the distal end to the proximal end, the forward portion comprising a first conductive material; a ring-shaped aft portion, defining a hollow center, configured to substantially surround a portion of the forward portion when the forward portion is located inside of the hollow center, wherein (1) the aft portion includes a pneumatic reaction region disposed on a radially-extensive segment of the aft portion for receiving a biasing flow of a pressurized gas and separating the electrode from a nozzle during pilot arc initiation (2) the aft portion comprises a second material that is different from the first material; and an emitter disposed in the proximal end of the forward portion. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of manufacturing an electrode usable in a plasma arc torch, the method comprising:
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selecting a first bar stock of a first conductive material to form an aft portion of the electrode; selecting a second bar stock of a second conductive material to form a forward portion of the electrode, wherein the first bar stock has a larger diameter than the second bar stock and the second conductive material is different from the first conductive material; forming the aft portion from the first conductive material, the aft portion is ring shaped with a radially-extensive segment having a pneumatic reaction region disposed thereon, the pneumatic reaction region configured to receive a bias flow of a pressurized gas to separate the electrode from a nozzle during pilot arc initiation, the aft portion defining a proximal end, a distal end and an aft diameter; forming the forward portion from the second conductive material such that the forward portion is coupled to the proximal end of the aft portion, the forward portion defining a forward diameter, wherein the aft diameter of the aft portion is greater than the forward diameter of the forward portion, and locating an emitter in the forward portion. - View Dependent Claims (12)
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13. A method of manufacturing an electrode usable in a plasma arc torch, the method comprising:
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selecting a first conductive material and a second conductive material that is different from the first material; forming a ring-shaped aft portion from the first conductive material, the ring-shaped aft portion defining a hollow center and a radially-extensive segment having a pneumatic reaction region disposed thereon, the pneumatic reaction region configured to receive a biasing flow of a pressured gas to separate the electrode from a nozzle during pilot arc initiation; forming an elongated forward portion from the second conductive material, the elongated forward portion defining a proximal end and a distal end; fitting the elongated forward portion through the hollow center of the ring-shaped aft portion such that the ring-shaped aft portion substantially surrounds at least a portion of the forward portion; and locating an emitter in the proximal end of the forward portion. - View Dependent Claims (14, 15, 16, 17)
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Specification