Cartridge for liquid-cooled plasma arc torches

Abstract

The present application relates to a barrel for a liquid-cooled plasma arc torch. A consumable barrel frame for a liquid-cooled plasma arc torch is provided. The consumable barrel frame includes an insulating body configured to be disposed between a torch head and a barrel tip. The consumable barrel also includes a first cooling channel disposed in the body and configured to conduct a first fluid flow received from the torch head to contact a component of the barrel tip connected to the barrel frame. The consumable barrel also includes a first return channel disposed in the body and configured to conduct at least a portion of the first fluid flow from the component to the torch head. The first cooling channel and the first return channel are non-concentric with respect to a central longitudinal axis of the body.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 200913, filed on August 4, 2015, the entire contents of which are owned by the assignee of this application and are incorporated herein by reference in their entirety. This application is a divisional application, the parent application number of which is 201680045667.0, the filing date of which is August 4, 2016, and the invention name is "Cartridge for Liquid-Cooled Plasma Arc Torch". Technical Field

[0003] The present invention relates generally to cartridges for liquid cooled plasma arc torches and, more particularly, to one or more replaceable, low-cost cartridges having integrally bonded components. Background Art

[0004] Heat treatment torches such as plasma arc torches are widely used for high temperature processing (e.g., heating, cutting, scraping, and marking) of materials. A plasma arc torch generally includes a torch head, an electrode mounted in the torch head, a radioactive insert disposed in an opening in the electrode, a nozzle having a central outflow orifice mounted in the torch head, a shroud, electrical connections, passages for cooling, passages for arc control fluids (e.g., plasma gas), and a power source. A swirl ring can be used to control the fluid flow pattern in a plasma chamber formed between the electrode and the nozzle. In some torches, a retaining cap is used to hold the nozzle and / or swirl ring in the plasma arc torch. In operation, the torch generates a plasma arc, which is a converging jet of ionized gas having a high temperature and sufficient momentum to help assist in the removal of molten metal. The gas used in the torch may be non-reactive (e.g., argon or nitrogen), or reactive (e.g., oxygen or air).

[0005] Existing plasma cutting systems include a large array of individual consumables that can be used in conjunction with different currents and / or operating modes, which are repeatedly assembled and disassembled by users in the field to perform heat treatment operations. The large number of consumable options requires the user to have a large number of parts and inventory, and can confuse the user and increase the possibility of installing inaccurate consumables. The large number of consumable options can also cause long torch setup times and make it difficult to transition between cutting processes that require different consumable arrangements in the torch, which are typically run one component at a time in the field. For example, prior to a cutting operation, selecting and installing the correct set of consumables for a particular cutting task can be cumbersome and time consuming. In addition, selecting, assembling, and installing these components in the field can cause alignment problems or compatibility issues when old components are used in conjunction with new components. During torch operation, existing consumables may experience performance problems, such as failure to maintain proper consumable alignment and spacing. In addition, current consumables include a large amount of expensive materials (e.g., Vespel TM), and generally require relatively complex manufacturing processes, which result in high manufacturing costs and hinder their widespread commercialization, production, and adoption. What is needed is a new and improved consumable platform for liquid-cooled plasma arc torches that reduces manufacturing cost and time, reduces part count, improves system performance (e.g., component alignment, cut quality, consumable life, variability / versatility, etc.), and simplifies installation and use of the consumables by the end user. Summary of the invention

[0006] The present invention provides one or more integrally combined cost-effective barrel designs for liquid-cooled plasma arc torches. In general, since the barrel includes a set of two or more consumable components, it provides ease of use and shortens the time to install into the plasma arc torch compared to installing / replacing each consumable component independently. The use of consumable barrels also reduces the possibility that an operator puts in the wrong consumable parts, contaminates the parts during installation, and / or accidentally puts a poor or bad part back on the torch. These advantages eliminate the need for an experienced operator to operate a liquid-cooled plasma arc torch. In addition, the barrel improves component alignment, cutting consistency, and cutting quality experience for a liquid-cooled torch. In addition, the use of consumable barrels enhances the supplier experience because fewer consumable parts need to be stocked and kept on hand. In some cases, suppliers can repurchase used barrels and recycle components for other uses. However, manufacturing and material costs can hinder the widespread commercialization and production of barrels. The present invention solves this problem by providing one or more cost-effective barrel designs that facilitate the commercialization and production of barrels and improve their installation.

[0007] In one aspect, the invention features a consumable barrel frame for a liquid-cooled plasma arc torch, the consumable barrel frame including an insulating body configured to be disposed between a torch head and a barrel tip, a first cooling passage disposed in the body configured to conduct a first fluid flow received from the torch head to contact a component of the barrel tip connected to the barrel frame, and a first return passage disposed in the body configured to conduct at least a portion of the first fluid flow from the component to the torch head. The first cooling passage and the first return passage are non-concentric about a central longitudinal axis of the body.

[0008] In some embodiments, the consumable barrel frame further includes a torch engagement feature configured to radially secure the barrel tip to the torch head in a predetermined orientation. The first cooling channel may be configured to be substantially aligned with a corresponding first cooling channel of the torch head when the barrel tip is radially secured to the torch head via the torch engagement feature. The first liquid cooling channel may be adapted to conduct cooling liquid from the torch head into the barrel tip. The first return channel may be configured to be substantially aligned with a corresponding first return channel of the torch head when the barrel tip is radially secured to the torch head via the torch engagement feature. The first return channel may be adapted to return cooling liquid from the barrel tip to the torch head.

[0009] In some embodiments, the consumable cartridge frame further comprises a central channel disposed in the insulating body and concentric with respect to the central longitudinal axis of the insulating body, the central channel being configured to perform at least one of (i) conducting the first fluid flow from the torch head to the electrode, or (ii) transferring the current from the torch head to the electrode. The consumable cartridge frame may further comprise: a second cooling channel disposed in the insulating body and configured to conduct at least a portion of the first fluid flow received from the torch head to contact a second member of the cartridge tip different from the first member; and a second return channel disposed in the insulating body and configured to conduct at least a portion of the first fluid flow from the second member to the torch head. The second cooling channel and the second return channel may be non-concentric with respect to the central longitudinal axis of the insulating body.

[0010] In some embodiments, the consumable barrel frame further comprises at least one gas channel disposed in the insulating body and configured to conduct the second fluid flow to the second member at the barrel tip. The at least one gas channel is non-concentric with respect to the central longitudinal axis of the insulating body. The second fluid flow may include a plasma gas flow or a shield gas flow. The second member may include one of a nozzle or a shield.

[0011] In some embodiments, the first fluid flow comprises a liquid coolant flow. In some embodiments, the member of the barrel tip comprises one of a nozzle or a shroud. In some embodiments, the first cooling channel and the first return channel extend longitudinally from a proximal region to a distal region of the insulating body and are non-overlapping.

[0012] In another aspect, a barrel frame for a plasma arc torch barrel for liquid cooling is provided. The barrel frame includes a barrel frame body having a central area, an inner surface, an outer surface, a proximal portion, and a distal portion, wherein the barrel frame body is at least substantially made of a non-conductive material. The barrel frame also includes a torch engagement docking surface located at the proximal portion of the barrel frame body, and the torch engagement docking surface is configured to engage a torch head. The barrel frame also includes a plurality of component alignment features formed in the central area, and a plurality of channels between the proximal portion and the distal portion. The plurality of channels are located at a central axis that deviates from the central area. The plurality of channels are configured to guide liquid and gas through the barrel frame.

[0013] In some embodiments, one or more component alignment features are configured to align the nozzle with the inner surface of the barrel frame, and the nozzle is matched to the inner surface. One or more component alignment features may include one or more steps, which are configured to align the nozzle axially and match to the barrel frame. One or more component alignment features may include a diameter that varies along the section of the inner surface of the barrel frame to align the nozzle radially and match to the barrel frame. In some embodiments, one or more component alignment features are configured to align the outer surface of the shield with the barrel frame, and the shield is matched to the outer surface.

[0014] In some embodiments, the plurality of channels include a shield gas channel configured to provide a metered shield gas flow therethrough. The cartridge frame may further include a baffle and a shield swirl ring disposed at a distal portion of the cartridge frame body. The baffle and the shield swirl ring may be in fluid communication with the shield gas channel to adjust at least one parameter of the shield gas flow therethrough.

[0015] In some embodiments, the cartridge frame further comprises an opening on an inner surface of the cartridge frame. The plurality of channels comprise a coolant channel configured to supply liquid coolant to the nozzle, and the opening is in fluid communication with the coolant channel to conduct the liquid coolant away from the nozzle. In some embodiments, the cartridge frame further comprises an opening on an outer surface of the cartridge frame. The plurality of channels each comprise a coolant channel configured to supply liquid coolant to the shroud, and the opening is in fluid communication with the coolant channel to conduct the liquid coolant away from the shroud.

[0016] In some embodiments, the cartridge frame further includes a drain passage extending from an inner surface to an outer surface of the cartridge frame.

[0017] In another aspect, a consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge includes a body portion having a distal region and a proximal region, a tip portion located at the distal region, the tip portion including a plasma emitter and a plasma arc retractor, and two or more non-concentric channels extending from the proximal region to the tip portion in the distal region of the body.

[0018] In some embodiments, two or more non-concentric channels are provided in a cartridge frame made of an insulating material. In some embodiments, the cartridge frame forms an interface between the tip portion and the torch head.

[0019] In some embodiments, the tip portion includes at least one of a nozzle, a shield, or an electrode. In some embodiments, the two or more non-concentric channels include (i) a first set of channels including a coolant channel and a return channel in fluid communication with the nozzle to supply liquid coolant to and from the nozzle, and (ii) a second set of channels including a coolant channel and a return channel in fluid communication with the shield to supply at least a portion of the liquid coolant to and from the shield. In some embodiments, the two or more non-concentric channels include a plasma gas channel to supply plasma gas to the passage between the swirl ring and the nozzle. In some embodiments, the two or more non-concentric channels include a shielding gas channel that supplies shielding gas to the passage between the shield and the nozzle. In some embodiments, the consumable barrel also includes a central channel in fluid communication with the electrode, wherein the central channel is configured to transfer at least one of a liquid coolant or an electric current to the electrode.

[0020] On the other hand, a consumable barrel frame for a liquid-cooled plasma arc torch is provided. The consumable barrel frame includes a first interface configured to be connected to a torch head of the plasma arc torch, and a second interface axially spaced apart from the first surface along the longitudinal axis of the consumable, wherein the second interface is configured to be connected to a plurality of components, including at least a nozzle, a shield, an electrode, and a swirl ring. The consumable barrel frame also includes a body portion extending along the longitudinal axis to connect the first interface to the second interface. The body portion includes a plurality of channels configured to transfer liquid and gas between the torch head and the plurality of components through the first interface and the second interface.

[0021] In some embodiments, the first interface includes an alignment feature configured to be radially secured to the torch head in a predetermined orientation. The plurality of channels may be adapted to align with corresponding channels in the torch head in a predetermined orientation to transfer liquids and gases between the torch head and the plurality of components. In some embodiments, two or more of the plurality of channels are non-concentric.

[0022] In some embodiments, the second interface includes (i) at least one step on the inner surface of the consumable barrel frame that matches and aligns the nozzle axially to the barrel frame, and (ii) at least one section of the inner surface of the consumable barrel frame having a varying diameter to match and align the nozzle radially to the barrel frame. The second interface may also include an alignment feature configured to align the shield axially and radially with the barrel frame and match the shield to the barrel frame. The alignment feature may include at least one of a step or a matching section on the outer surface of the consumable barrel.

[0023] In some embodiments, the consumable cartridge frame may further include a cavity disposed in the body portion proximate the first interface. The cavity is configured to receive a radio frequency identification (RFID) tag for communicating with a reader of the torch head.

[0024] On the other hand, a barrel frame for a plasma arc torch barrel consumable for liquid cooling is provided. The barrel frame includes a barrel frame body having a proximal portion, a distal portion, an outer surface, and an inner opening to a central channel in the barrel frame body. The barrel frame also includes a shielding gas channel extending from the proximal portion of the barrel frame body to the distal portion of the barrel frame body, a nozzle coolant supply channel extending from the proximal portion of the barrel frame body to the inner opening, and a nozzle coolant return channel extending from the inner opening of the barrel frame body to the proximal portion. The barrel frame also includes a circumferential coolant flow channel in the outer surface of the barrel frame body, a shield coolant supply channel extending from the proximal portion to the circumferential coolant flow channel, and a shield coolant return channel extending from the circumferential coolant flow channel to the proximal portion.

[0025] On the other hand, a liquid-cooled consumable barrel for a plasma arc torch is provided. The barrel includes: (i) an electrode, (ii) a swirl ring having a first outer retaining feature and a second outer retaining feature on an outer surface, wherein the electrode is fixed to the swirl ring, and (iii) a nozzle having an inner retaining feature on an inner surface, wherein the inner retaining feature of the nozzle matches the first outer retaining feature of the swirl ring. The barrel also includes a barrel frame having an inner retaining feature on an inner surface and an outer retaining feature on an outer surface. The inner retaining feature of the barrel frame matches the second outer retaining feature of the swirl ring. The barrel also includes a shield having an inner retaining feature on an inner surface that matches the outer retaining feature of the barrel frame. At least the nozzle, the swirl ring, the barrel frame and the shield are axially fixed to a predetermined position when matched with each other to provide at least one liquid flow path from the barrel frame to the shield or the nozzle.

[0026] In some embodiments, the electrode and the nozzle are aligned axially and radially with respect to each other without physical contact between the electrode and the nozzle. In some embodiments, the nozzle and the shroud are aligned axially and radially with respect to each other without physical contact between the nozzle and the shroud.

[0027] In some embodiments, at least one of the shroud, nozzle, or swirl ring mates directly with the cartridge frame. The electrode may mate indirectly with the cartridge frame via at least one of the swirl ring or electrode insulator.

[0028] In some embodiments, the match between the inner retaining feature of the nozzle and the first outer retaining feature of the swirl ring aligns the nozzle with the swirl ring in radial direction. In some embodiments, the match between the inner retaining feature of the barrel frame and the second outer retaining feature of the swirl ring provides at least one of the axial alignment or radial alignment between the barrel frame and the swirl ring. In some embodiments, the match between the inner retaining feature of the shroud and the outer retaining feature of the barrel frame provides at least one of the axial alignment or radial alignment between the barrel frame and the shroud. In some embodiments, the barrel frame also includes a second inner retaining feature on the inner surface configured to match the outer retaining feature on the outer surface of the nozzle. The match between the barrel frame and the nozzle provides at least one of the axial alignment or radial alignment between the barrel frame and the nozzle.

[0029] In some embodiments, the nozzle is a non-discharge nozzle coupled to a nozzle jacket. In some embodiments, the nozzle is a discharge nozzle coupled to a nozzle bushing.

[0030] On the other hand, a liquid-cooled consumable barrel for a plasma arc torch is provided. The barrel includes: (i) an electrode, (ii) a swirl ring having an outer retaining feature on an outer surface and an inner retaining feature on an inner surface, wherein the electrode is fixed to the inner retaining surface of the swirl ring, and (iii) a nozzle having an outer retaining feature on an outer surface. The barrel also includes a barrel frame having a first inner retaining feature and a second inner retaining feature on an inner surface and an outer retaining feature on an outer surface. The first inner retaining feature of the barrel frame matches the outer retaining feature of the swirl ring, and the second inner retaining feature of the barrel frame matches the outer retaining feature of the nozzle. The barrel also includes a shield having an inner retaining feature on an inner surface that matches the outer retaining feature of the barrel frame. At least the nozzle, the swirl ring, the barrel frame and the shield are axially fixed in a predetermined position when matched.

[0031] In another aspect, a consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge includes a non-conductive cartridge frame, and a group of conductive consumable members that partially define a plasma chamber. The group of conductive members is attached to the cartridge frame. The consumable cartridge is composed of at least 50% non-conductive material by volume. In some embodiments, the consumable cartridge is composed of approximately 60% to 80% non-conductive material by volume.

[0032] In some embodiments, the consumable cartridge is a single-use cartridge. The set of conductive consumable components cannot be independently disposed of or used after being attached to the cartridge frame.

[0033] In some embodiments, the cartridge frame includes liquid and gas passages in fluid communication with the set of conductive members. The liquid and gas passages are non-concentric about a central longitudinal axis of the cartridge frame.

[0034] In some embodiments, the set of conductive consumable components includes a shield, a nozzle, and an electrode.

[0035] In another aspect, a method of manufacturing an integral consumable cartridge from a plurality of components is provided. The method includes axially and radially securing an electrode to a swirl ring, axially and radially securing a retaining feature on an outer surface of the swirl ring to at least one of a matching retaining feature on an inner surface of a cartridge frame or a nozzle, and axially and radially securing a retaining feature on an outer surface of the cartridge frame to a matching retaining feature on an inner surface of a shroud. The consumable components are axially and radially mounted relative to each other to position at least one internal fluid passage of a cartridge frame having (i) a fluid passage of a nozzle or (ii) a fluid passage of a shroud.

[0036] In some embodiments, axially and radially securing the electrode to the scroll ring includes axially and radially securing the electrode to an electrode insulator, and axially and radially securing the electrode insulator to the scroll ring.

[0037] In some embodiments, the method further comprises aligning the plasma gas passage in the barrel frame with the gas passage between the swirl ring and the nozzle in a radial direction. In some embodiments, the method further comprises aligning the shield gas passage in the barrel frame with the gas passage between the nozzle and the shroud in a radial direction. In some embodiments, the method further comprises aligning the center passage in the barrel frame with the electrode in a radial direction. In some embodiments, the method further comprises aligning the first coolant passage and the second coolant passage in the barrel frame with the nozzle in a radial direction, and aligning the third coolant passage and the fourth coolant passage in the barrel frame with the shroud in a radial direction.

[0038] In some embodiments, the method further comprises forming the swirl ring by die casting using zinc. In some embodiments, the method further comprises forming the barrel frame by molding using a non-conductive material. In some embodiments, the method further comprises forming the shield by stamping using a conductive material. In some embodiments, the axial and radial securing of the plurality of components is by one or more of snap fit, press fit or interference, crimping, gluing, cementing, or welding.

[0039] In another aspect, a method for assembling a liquid-cooled consumable cartridge for a plasma arc cutting torch is provided. The method includes providing an insulating cartridge frame having a central region, an outer surface, a distal end, and a proximal end. The method also includes coupling a vortex member to the cartridge frame in the central region, coupling an electrode to the cartridge frame in the central region, coupling a nozzle to the cartridge frame in the central region, and coupling a shield to the cartridge frame at the outer surface.

[0040] In some embodiments, coupling the vortex member to the barrel frame includes matching the outer surface of the vortex member to the inner surface of the barrel frame, which provides at least one of the axial alignment or radial alignment of the vortex member with the barrel frame. In some embodiments, coupling the nozzle to the barrel frame includes coupling the outer surface of the nozzle to the inner surface of the barrel frame, which provides at least one of the axial alignment or radial alignment of the nozzle with the barrel frame. In some embodiments, coupling the shield to the barrel frame at the outer surface provides at least one of the axial alignment or radial alignment of the shield with the barrel frame. In some embodiments, the method further includes coupling the electrode to the barrel frame via at least one of the vortex member and the electrode insulator. In some embodiments, the coupling aligns at least one internal fluid passage of the barrel frame with (i) the fluid passage of the nozzle or (ii) the fluid passage of the shield.

[0041] In some embodiments, the method further includes positioning a baffle and a second scroll member at a distal end of the cartridge frame in the central region.

[0042] A consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge includes a cartridge frame including a proximal end having an end face, a distal end, and a body having a central longitudinal axis extending therethrough. The cartridge is configured to form a radio frequency identification (RFID) interface with a torch head. The consumable cartridge also includes an arc emitter and an arc retractor attached to the cartridge frame at the distal end, and an RFID mounting feature formed on or in the cartridge frame near the end face. The RFID mounting feature is non-concentric with the central longitudinal axis of the body. The consumable cartridge also includes: an RFID tag disposed in or on the RFID mounting feature for transmitting information about the cartridge to a reading device in the torch head when the cartridge is connected to the torch head; and a clocking feature configured to rotationally align the RFID tag with the reading device in the torch when the cartridge is connected to the torch head.

[0043] In some embodiments, the RFID mounting feature includes a cavity disposed in the body of the barrel frame. The RFID tag can be embedded in the cavity of the body of the barrel frame and surrounded by the insulating material of the body. In some embodiments, the end face is generally flat to allow an RFID reader to interrogate the RFID tag from outside the plasma arc torch. In some embodiments, the RFID tag can be read from inside or outside the plasma arc torch.

[0044] In some embodiments, the body of the cartridge frame is constructed of an insulating material. In some embodiments, the body of the cartridge frame includes at least one passage for conducting liquid coolant therethrough. The at least one passage can be configured to substantially align with a corresponding passage of the torch head when rotationally aligned by the synchronization feature to conduct liquid coolant between the torch head and the cartridge.

[0045] In some embodiments, when rotationally aligned, the RFID tag in the barrel frame and the reading device in the torch head are oriented such that the central axis extends through a centerline of the RFID tag and a centerline of the reading device. In some embodiments, when rotationally aligned, a first distance between the RFID tag and the reading device is less than a second distance between the RFID tag and an adjacent metallic material disposed in the torch head or barrel.

[0046] In some embodiments, the synchronization feature includes a cavity configured to receive a synchronization pin extending from the torch head.

[0047] In another aspect, a consumable barrel for a liquid-cooled plasma arc cutting torch is provided. The consumable barrel includes a barrel tip located at a first portion of the barrel. The barrel tip has an electrode, a nozzle, and a shield. The consumable barrel includes a plasma gas inlet opening at a second portion of the consumable barrel, a shield gas inlet opening at the second portion, an electrode coolant inlet opening at the second portion, a nozzle coolant inlet opening and a nozzle coolant outlet opening at the second portion, and a shield coolant inlet opening and a shield coolant outlet opening at the second portion.

[0048] In some embodiments, the second portion comprises an end surface of a proximal portion of the barrel.The end surface may be substantially flat.

[0049] In some embodiments, the plasma gas inlet opening, the shield gas inlet opening, the nozzle coolant inlet opening, the nozzle coolant outlet opening, the shroud coolant inlet opening, and the shroud coolant outlet opening are non-concentric about a central longitudinal axis of the barrel.

[0050] In some embodiments, the plasma gas inlet opening is configured to align with a corresponding opening of the torch head to direct the plasma gas flow from the torch head to the nozzle. In some embodiments, the shield gas inlet opening is in fluid communication with the shroud. The shield gas inlet opening is configured to align with a corresponding opening of the torch head to direct the shield gas flow to the shroud. In some embodiments, the electrode coolant inlet opening maintains at least one of electrical communication or fluid communication with the electrode. The electrode coolant inlet opening is configured to align with a corresponding opening of the torch head to direct at least one of liquid coolant or electric current to the electrode. In some embodiments, the nozzle coolant inlet opening and the nozzle coolant outlet opening are in fluid communication with the nozzle. The nozzle coolant inlet opening and the nozzle coolant outlet opening are configured to align with corresponding openings in the corresponding openings on the torch head to direct liquid coolant between the torch head and the nozzle. In some embodiments, the shroud coolant inlet opening and the shroud coolant outlet opening are in fluid communication with the shroud. The shroud coolant inlet opening and the shroud coolant outlet opening are configured to align with corresponding openings in the corresponding openings on the torch head to direct liquid coolant between the torch head and the shroud. In some embodiments, the nozzle coolant outlet opening is fluidly connected to the shroud coolant inlet opening.

[0051] In some embodiments, the consumable cartridge further includes a synchronization pin receiving portion at the second portion. The synchronization pin receiving portion is configured to receive a synchronization pin of the torch head to secure the cartridge to the torch head in a predetermined orientation.

[0052] In some embodiments, the consumable barrel also includes a barrel frame having an insulating body. The barrel frame is coupled to the barrel tip. The plasma gas inlet opening, the shield gas inlet opening, the electrode coolant inlet opening, the nozzle coolant inlet opening, the nozzle coolant outlet opening, the shield coolant inlet opening, and the shield coolant outlet opening are located at the proximal end of the insulating body. In some embodiments, the consumable barrel also includes a non-concentric cavity disposed in the insulating body of the barrel frame, and a radio frequency identification (RFID) tag disposed in the cavity.

[0053] On the other hand, a consumable barrel for a liquid-cooled plasma arc cutting torch is provided. The consumable barrel includes a barrel tip located at a first portion of the barrel. The barrel tip has an electrode, a nozzle and a shield. The consumable barrel also includes a barrel frame at a second portion of the barrel. The barrel frame includes a distal end connected to the barrel tip, and a proximal end. The barrel frame includes a plasma gas inlet opening configured to maintain fluid communication with the nozzle to introduce a plasma gas flow into the proximal end of the nozzle, a shield gas inlet opening configured to maintain fluid communication with the shield to introduce a shield gas flow into the proximal end of the shield, and an electrode interface configured to maintain electrical communication or fluid communication with the electrode to introduce at least one of a coolant flow or an electric current into the proximal end of the electrode. The barrel frame also includes a nozzle coolant inlet opening and a nozzle coolant outlet opening configured to circulate a coolant flow between the barrel frame and the nozzle, and a shield coolant outlet opening configured to circulate a coolant flow between the barrel frame and the shield.

[0054] In another aspect, a torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body, and a torch insulator having a substantially non-conductive insulating body. The torch insulator is coupled to the torch body. The torch insulator includes: (i) a first liquid coolant channel disposed within the insulating body and configured to conduct a fluid flow from the torch head along a first pre-existing flow path to a consumable barrel; (ii) a first liquid return channel disposed within the insulating body and configured to return at least a portion of the fluid flow from the barrel to the torch head along the first pre-existing flow path; and (iii) a gas channel disposed within the insulating body and configured to conduct a first gas flow from the torch head along a second pre-existing flow path to the barrel. The first pre-existing flow path and the second pre-existing flow path are fluidically isolated from each other.

[0055] In some embodiments, the torch head further comprises an alignment feature configured to radially secure the torch head to the barrel in a predetermined orientation to maintain a first pre-existing flow path and a second pre-existing flow path extending through the torch insulator and the barrel. The first liquid coolant passage may be configured to be substantially aligned with a corresponding first liquid coolant passage of the barrel when the torch head is radially secured to the barrel via the alignment feature. The first liquid return passage may be configured to be substantially aligned with a corresponding first liquid return passage of the barrel when the torch head is radially secured to the barrel via the alignment feature. The first pre-existing flow path may include a first liquid coolant passage of the torch head, a corresponding first liquid coolant passage of the barrel, a corresponding first liquid return passage of the barrel, and a first liquid return passage of the torch head.

[0056] In some embodiments, the torch insulator further comprises a gas valve embedded in the insulating body, the gas valve being in fluid communication with the gas passage, the gas valve being configured to select one of a plurality of gases to be supplied to the gas passage. In some embodiments, the torch insulator further comprises a second gas passage disposed in the insulating body and configured to conduct a second gas flow from the torch head to the barrel along a third pre-existing flow path. The second pre-existing flow path and the third pre-existing flow path are fluidically isolated from each other. In some embodiments, the torch insulator further comprises a central channel disposed in the insulating body, the central channel being configured to provide at least one of (i) an electric current or (ii) at least a portion of a fluid flow from the torch head to the barrel. In some embodiments, the torch insulator further comprises an electrical passage disposed in the insulating body, the electrical passage being configured to receive an ohmic contact connection that establishes an ohmic contact between the torch head and the barrel.

[0057] In some embodiments, the welding torch insulator also includes: (i) a current ring at the distal end of the insulating body, the current ring being configured to receive an arc pilot current from the barrel; and (ii) an arc pilot channel being configured to receive an arc pilot connector, the arc pilot connector being electrically connected to the current ring to transfer the arc pilot current from the barrel to the welding torch head.

[0058] In some embodiments, the torch insulator further comprises: (i) a second liquid coolant channel disposed in the insulating body and configured to conduct at least a portion of the fluid flow from the torch head along the first pre-existing flow path to the barrel; (ii) a second liquid return channel disposed in the insulating body and configured to return at least a portion of the fluid flow from the barrel to the torch head along the first pre-existing flow path; and (iii) a distribution channel disposed in the insulating body to connect the first liquid return channel with the second liquid coolant channel. The first pre-existing flow path may flow through a series of channels in the insulating body, including the first liquid coolant channel, the first liquid return channel, the distribution channel, the second liquid coolant channel, and the second liquid return channel.

[0059] In some embodiments, the first liquid coolant channel, the first liquid return channel, and the gas channel are non-concentric with respect to a longitudinal axis extending through the insulator body.

[0060] On the other hand, a torch head for a liquid-cooled plasma arc torch is provided. The torch head includes: (i) a torch insulator having an insulating body; (ii) a first cooling channel and a third cooling channel disposed in the insulating body, each configured to conduct a first fluid flow from the torch head to the barrel; (iii) a second cooling channel and a fourth cooling channel disposed in the insulating body, each configured to return at least a portion of the first fluid flow from the barrel to the torch head; and (iv) a first distribution channel disposed in the insulating body, connecting the second cooling channel and the third cooling channel. The first distribution channel is configured to guide the first fluid flow from the second channel to the third channel.

[0061] In some embodiments, the first distribution channel is oriented circumferentially to connect the second cooling channel and the third cooling channel. In some embodiments, the first cooling channel, the second cooling channel, the third cooling channel, and the fourth cooling channel are non-concentric about a longitudinal axis extending through the insulating body. In some embodiments, each of the first cooling channel, the second cooling channel, the third cooling channel, and the fourth cooling channel is asymmetric relative to a central longitudinal axis extending through the insulating body.

[0062] In yet another aspect, a torch head for a liquid-cooled plasma arc torch is provided. The torch head includes: (i) a torch insulator having an insulating body including a proximal end and a distal end; (ii) a plurality of gas and liquid passages extending generally from the proximal end to the distal end of the insulating body; (iii) a cavity in the insulating body; and (iv) a communication device including a circuit board and a radio frequency identification (RFID) antenna coil. The RFID antenna coil is electrically connected to the circuit board and is positioned near the distal end of the communication device. The communication device is located in the cavity such that the RFID antenna coil is located at the distal end of the insulating body.

[0063] In some embodiments, the communication device further comprises a sealed housing for preventing liquid from entering therein. In some embodiments, the circuit board of the communication device is configured to provide power to the antenna coil and read the RFID signal received by the antenna coil. The antenna coil may be positioned at the end face of the far end of the communication device. In some embodiments, the communication device further comprises a connector at the near end of the communication device.

[0064] In some embodiments, the plurality of gas and liquid channels and cavities are non-concentric about a central longitudinal axis of the insulating body. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] The advantages of the present invention described above, together with other advantages, may be better understood by referring to the following description taken in conjunction with the accompanying drawings. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

[0066] 1 a and 1 b are exploded and assembled views, respectively, of a liquid-cooled plasma arc torch 10 generally including a torch head and a barrel according to an exemplary embodiment of the present invention.

[0067] Figure 2 is a cross-sectional view of the assembled plasma arc torch of FIG. 1 b according to an exemplary embodiment of the present invention.

[0068] Figure 3 is a view of a proximal end of the torch head of FIG. 1 according to an exemplary embodiment of the present invention.

[0069] Figure 4 is a view of a distal end of the torch head of FIG. 1 according to an exemplary embodiment of the present invention.

[0070] Figure 5 1 is an exemplary design of a cathode of the torch head of FIG. 1 according to an exemplary embodiment of the present invention.

[0071] Figure 6 1 is an exemplary design of a coolant tube of the torch head of FIG. 1 according to an exemplary embodiment of the present invention.

[0072] Figure 7 1 is a diagram oriented to illustrate an exemplary arc pilot current path between a torch head and a barrel of a plasma arc torch according to an exemplary embodiment of the present invention. Figure 2 Cross-sectional view of a plasma arc torch.

[0073] Figure 8 oriented to show an exemplary ohmic contact path according to an exemplary embodiment of the present invention. Figure 2 Cross-sectional view of a plasma arc torch.

[0074] Fig. 9 1 is an exemplary design of a current loop in the torch head of FIG. 1 according to an exemplary embodiment of the present invention.

[0075] Fig.10 Detailed Description of the Invention ...

[0076] 11a and b are diagrams oriented to show an exemplary shield gas flow path from a torch head to a barrel of a plasma arc torch according to an exemplary embodiment of the present invention. Figure 2 Cross-sectional view of a plasma arc torch.

[0077] 12a-c are diagrams oriented to show an exemplary plasma gas flow path from a torch head to a barrel of a plasma arc torch according to an exemplary embodiment of the present invention. Figure 2 Cross-sectional view of a plasma arc torch.

[0078] 13a and b are diagrams oriented to show an exemplary liquid coolant flow path circulating between a torch head and a barrel of a plasma ring welding torch according to an exemplary embodiment of the present invention. Figure 2 Cross-sectional view of a plasma arc torch.

[0079] 14a and b are exemplary profile and proximal side views, respectively, of a cathode block of a torch head according to an exemplary embodiment of the present invention.

[0080] Fig.15 is a view of a proximal end of a cartridge frame of the cartridge of FIG. 1 according to an exemplary embodiment of the present invention.

[0081] Fig.16 FIG. 1 is a cross-sectional view of an exemplary design of the retaining cap 120 of FIG. 1 according to an exemplary embodiment of the present invention.

[0082] Fig.17 is a cross-sectional view of the cartridge of FIG. 1 according to an exemplary embodiment of the present invention.

[0083] Fig.18 According to an exemplary embodiment of the present invention Fig.17 An exemplary design of a cartridge frame of a cartridge.

[0084] Fig.19 According to an exemplary embodiment of the present invention Fig.17 An exemplary design of a cartridge electrode.

[0085] Fig. 20 For attachment to an exemplary embodiment of the present invention Fig.17 Cross-sectional view of the baffle and protective swirl ring on the barrel frame of the barrel.

[0086] Fig.21 According to an exemplary embodiment of the present invention Fig.17 A cross-sectional view of the protective swirl ring of the barrel.

[0087] Fig. 22 1 is a diagram showing various channel openings according to an exemplary embodiment of the present invention. Fig.17 A perspective view of the barrel frame of a barrel.

[0088] Fig.23 According to an exemplary embodiment of the present invention Fig.17 Example design of a swirl ring for a cartridge.

[0089] 24a and 24b are respectively Fig.17 External view of the non-discharge nozzle and nozzle jacket of the cartridge.

[0090] Fig.25 According to an exemplary embodiment of the present invention Fig.17 A cross-sectional view of the shield of the barrel.

[0091] Fig.26 1 is an exemplary exhaust sleeve compatible with the torch head of the plasma arc torch of FIG. 1 according to an exemplary embodiment of the present invention.

[0092] 27a and 27b are respectively Fig.26 External view of the cartridge's nozzle bushing and discharge nozzle.

[0093] Fig.28 1 is another exemplary cartridge frame that may be suitably configured to form a cartridge that is compatible with the torch head of FIG. 1 in accordance with an exemplary embodiment of the present invention.

[0094] Fig.29 is an exemplary discharge cartridge including a non-flat proximal end according to an exemplary embodiment of the present invention.

[0095] Fig.30 According to an exemplary embodiment of the present invention Fig.17 Exploded view of the cartridge.

[0096] Fig.31 FIG. 1 is a diagram showing exemplary positions of a communication device and a signaling device according to an exemplary embodiment of the present invention. Figure 2 Part of a plasma arc torch. DETAILED DESCRIPTION

[0097] The present invention provides a liquid-cooled plasma arc torch comprising a welding head and a consumable cartridge. In some embodiments, the consumable cartridge is a unitary component, wherein the components of the cartridge are not independently operable or disposable. Thus, if one component of the consumable cartridge needs to be replaced, the entire cartridge will be replaced. In some embodiments, the consumable cartridge is a "single-use" cartridge, wherein the cartridge is replaced by an operator after any of its components reaches the end of its useful life, rather than repairing and replacing separate consumables as with conventional torch designs. In some embodiments, the cartridge is replaced after a single period that may involve multiple arcs. In some embodiments, the cartridge is replaced after a single arc event.

[0098] 1a and 1b are exploded and assembled views, respectively, of a liquid-cooled plasma arc torch 10 that generally includes a torch head 102 and a barrel 104 according to an exemplary embodiment of the present invention. The barrel 104, which includes a plurality of consumable torch components, has a proximal end (region) 14 and a distal end (region) 16 along a central longitudinal axis A of the plasma arc torch 10. The torch head 102 includes a torch body 18, a proximal end (region) 20, and a distal end (region) 22 along the longitudinal axis A. The torch body 18 may be made of a conductive material such as brass. In some embodiments, the proximal end 14 of the barrel 104 is aligned with and secured to the distal end 22 of the torch head 102 by a retaining cap 120. In some embodiments, the proximal end 14 of the barrel 104 is matingly engaged / connected to the distal end 22 of the torch 102. For example, the proximal end 14 and the distal end 22 may be connected via at least seven different mating joints / joints / connection points. Other means of engagement between the torch head 102 and the barrel 104 are possible, including threaded connections, interference fits, snap fits, quick locks, etc. Thereafter, the proximal end of the component defines an area of ​​the component away from the workpiece (when the welding torch 10 is used to process the workpiece) along the longitudinal axis A, and the distal end of the component defines an area of ​​the component opposite the proximal end and close to the workpiece (when the welding torch 10 is used to process the workpiece).

[0099] Figure 2 1b is a cross-sectional view of the assembled plasma arc torch 10 of FIG. 1b according to an exemplary embodiment of the present invention. As shown, the interface 106 in FIG. 1 defines a boundary between the barrel 104 and the torch head 102 when the barrel 104 and the torch head 102 are joined to each other. The barrel 104, which is a substantially unitary element, includes a barrel tip, which includes an electrode 108 (i.e., an arc emitter), a nozzle 110 (i.e., an arc retractor), and a shield 114 concentrically disposed about a central longitudinal axis A. Components of the barrel tip may be connected to a barrel frame 112 of the barrel 104. In some embodiments, the barrel 104 also includes a swirl ring 150 disposed about the longitudinal axis A. hereinafter referred to Fig.15 and 17 -25 illustrates details about the barrel 104. The torch head 102 includes a torch insulator 118 disposed about the longitudinal axis A in the torch body 18. Figure 2 -14b illustrates details regarding the torch head 102.

[0100] Welding torch head

[0101] like Figure 2, the torch insulator 118 of the torch head 102 is generally disposed about a central longitudinal axis A in and surrounded by the torch body 18. The torch body 18 may be made of an electrically conductive material such as brass. The torch insulator 118, including a proximal end 21 and a distal end 23, may be made of an electrically insulating material such as plastic. At its proximal end 21, the torch insulator 118 may be coupled to one or more of the cathode 130, the communication device 122, the pilot arc connection 124, and the ohmic connection 131 while electrically insulating these components from each other and from the torch body 18. In some embodiments, at least one of the cathode 130, the communication device 122, the pilot arc connection 124, or the ohmic connection 131 is fixed to the torch insulator 118 (e.g., screwed or embedded in the torch insulator 118) so that they cannot be easily or quickly disconnected from the torch insulator 118. Additionally, the torch insulator 118 may include at least one gas opening 126a for coupling to a gas source (not shown) and introducing gas into the torch 10. The torch insulator 118 may also include at least one coolant opening 128a for coupling to a liquid coolant source (not shown) and introducing coolant into the torch 10. Figure 3 is a view of the proximal end 20 of the torch head 102 illustrating the various electrical, gas, and liquid openings at the proximal end 21 of the torch insulator 118 according to an exemplary embodiment of the present invention. Figure 4 is a view of the distal end 22 of the torch head 102 illustrating various electrical, gas, and liquid openings at the distal end 23 of the torch insulator 118 according to an exemplary embodiment of the present invention.

[0102] a. Connection between pilot arc and transfer arc

[0103] In one aspect, the torch insulator 118 can interconnect multiple components used to maintain a pilot arc current and / or a transferred arc current between the torch head 102 and the barrel 104. For example, the torch insulator 118 is adapted to connect the cathode 130, the coolant tube 116, the pilot arc connection 124, and the current ring 800 in a configuration that supports both pilot arc current and transferred arc current conduction between the torch head 102 and the barrel 104.

[0104] In some embodiments, the torch insulator 118 includes an opening 132a ( Figure 3 ) extends to the opening 132b (shown in FIG. 1 ) at the distal end 23 of the torch insulator 118. Figure 4 ) of the main channel 132 (shown in Figure 2 ). The main passage 132 may be centrally located within the torch insulator 118 such that it is concentric with respect to the central longitudinal axis A. The main passage 132 may extend substantially linearly within the insulator 118 to connect the openings 132a and 132b. The main passage 132 may be configured to receive at least a portion of the cathode 130. Figure 2As shown in , the cathode 130 can extend within the main passage 132 along the length of the torch insulator 118. In some embodiments, a cathode block locking member 250 is used to secure the cathode 130 to the main passage 132 within the torch insulator 118.

[0105] Figure 5 1 is an exemplary design of the cathode 130 of the torch head 102 according to an exemplary embodiment of the present invention. The cathode 130 includes a cathode fitting 602 having a distal end coupled to a cathode tube 604, and the cathode tube 604 having a distal end coupled to a cathode block 606. Each of the cathode fitting 602, the cathode tube 604, and the cathode block 606 can be made of a conductive material, such as brass or copper. In one exemplary design, the cathode fitting 602 and the cathode block 606 are made of brass, and the cathode tube 604 is made of copper.

[0106] like Figure 2 As shown in , the distal end of the cathode block 606 is electrically and / or physically coupled to the coolant tube 116 within the main passage 132 of the torch insulator 118. In some embodiments, the coolant tube 116 defines an O-ring groove that receives an O-ring 133 to form an interface between the outer surface of the coolant tube 116 and the inner surface of the cathode block 606. Thus, at least the proximal portion of the coolant tube 116 is inserted into the distal end of the cathode block 606. Generally, during operation, once the torch head 102 is coupled to the barrel 104, the coolant tube 116 distributes cooling fluid to the barrel 104. In some embodiments, the coolant tube 116 is configured to additionally transfer electrical current from the cathode 130 to the barrel 104, such as to the electrode 108 of the barrel 104. In some embodiments, the cathode block electrode tube 252 (which may be made of a non-conductive material) Figure 2 ) can be configured to be connected (e.g., threaded or sealed by an interference fit) to the cathode block 606 at its proximal end and the electrode 108 at its distal end. The resulting housing including the cathode 130, cathode block electrode tube 252, and electrode 108 generally surrounds the coolant tube 116 to contain the coolant flow therein.

[0107] Figure 6 1 is an exemplary design of a coolant tube 116 of a torch head 102 according to an exemplary embodiment of the present invention. The coolant tube 116 may be made of a conductive material such as brass. In some embodiments, the coolant tube 116 is attached (e.g., by screwing) to the distal end of the cathode block 606 so that it cannot be easily or quickly disconnected. In some other embodiments, the coolant tube 116 is attached (e.g., by interference fit) to the distal end of the cathode block 606 so that it can be easily or quickly disconnected. The coolant tube 116 may have an electrical connector around the outer surface at the proximal end 740, such as a Louvertac TMThe proximal end 740 of the coolant tube 116 is configured to mate with the cathode block 606. The Louvertac ring 720 is configured to conduct a cutting current transmitted from the inner surface of the cathode block 606 to the outer surface of the coolant tube 116 once the proximal end 740 of the coolant tube 116 is inserted and attached to the distal end of the cathode block 606. Alternatively, the coolant tube 116 may be fixedly secured to the cathode 130 via threads or other current transmission methods without the Louvertac ring 702. In some embodiments, the coolant tube 116 has an electrical connector around the outer surface at the distal end 742 of the coolant tube 116, such as a Louvertac TM The ring 704, distal end 742 is an end configured to mate with the inner surface of the electrode 108 once the torch head 102 is secured to the barrel 104. In some embodiments, the coolant tube 116 includes one or more longitudinal channels 744 on its outer surface below the Louvertac ring 704 at the distal end 742 to limit the pressure drop in the coolant flow between the coolant tube 116 and the electrode 108. In addition to conducting electrical current, the coolant tube 116 can be configured to conduct the coolant flow to the electrode 108. For example, the coolant tube 116 has an opening 745 at its proximal end 704 and an opening 746 at the distal end 742 to allow the coolant flow to enter and exit the coolant tube 116, respectively. In some embodiments, the Louvertac TM The use of a ring 704 or 704 at one or both of the distal end 742 or the proximal end 740 allows the coolant tube 116 to be slidably coupled to the torch head 102 and also allows the barrel 104 to be slidably coupled to the coolant tube 116. This feature is described in detail below.

[0108] In some embodiments, the torch insulator 118 includes a cavity 148 ( Figure 2 ), which has an opening 148a ( Figure 3 ). Figure 2 As shown in , the cavity 148 can be configured to receive the pilot arc connection 124. In some embodiments, the cavity 148 extends partially into the torch insulator 118 along the longitudinal axis A.

[0109] In some embodiments, a current ring 800 made of a conductive material (eg, brass) is located in the distal end 23 of the torch insulator 118 . Fig. 91 is an exemplary design of a current ring 800 of a torch insulator 118 in a torch head 102 according to an exemplary embodiment of the present invention. As shown, the current ring 800 has a ring portion 800a and a raised portion 800b. The ring portion 800a has a thin distal edge 802, and the raised portion 800b has a distal surface 805. The ring portion 800a of the current ring 800 can be concentrically positioned relative to the coolant tube 116 and the cathode 130 in the torch insulator 118, while the raised portion 800b of the current ring 800 can be oriented so that it electrically contacts and / or physically contacts the proximal end of the arc pilot connector 124 received in the cavity 148. In some embodiments, the current ring 800 is composed of a cathode insulator 804 ( Figure 2 ) is electrically insulated from the coolant tube 116 and the cathode 130, so that substantially no current is passed between the current loop 800 and the cathode 130 or between the current loop 800 and the coolant tube 116. Figure 4 In some embodiments shown in , at least one surface of the current ring 800 is exposed from the distal end 23 of the torch insulator 118 via the main electrical passage opening 132b so that components of the cartridge 104 can physically contact the current ring 800 when the cartridge 104 is attached to the torch head 102. For example, both the thin distal rim 802 of the ring portion 800a and the distal surface 805 of the raised portion 800b of the current ring 800 can be exposed from the opening 132b.

[0110] Figure 7 1 is a diagram of an exemplary arc pilot flow path 752 between the torch head 102 and the barrel 104 of the plasma arc torch 10, oriented to illustrate an exemplary embodiment of the present invention. Figure 21. A cross-sectional view of a plasma arc torch 10 of FIG. 1. To initiate a pilot arc, a maintenance current 752 associated with a high frequency high voltage (HFHV) signal is coupled to a power line from a power source (not shown) to the plasma arc torch 10. The pilot arc current 752 may be delivered from the power source to the cathode 130 via the cathode fitting 602. The cathode tube 604 connected to the cathode fitting 602 then delivers the pilot arc current 752 to the cathode block 606, which transfers the current to the coolant tube 116 via the Louvertac ring 702 at the proximal end 740 of the coolant tube 116. The pilot arc current 752 flows distally through the coolant tube 116 and is transferred to the inner surface of the electrode 108 via the Louvertac ring 704 at the distal end 742 of the coolant tube 116, thereby exciting the inner surface of the electrode 108. In an alternative embodiment, the pilot arc current is delivered from the cathode 130 to the electrode 108 without using the coolant tube 116, e.g., by a physical connection between the cathode 130 and the electrode 108. Once at the electrode 108, the pilot arc current path 752 causes a spark discharge in the plasma gas flowing in the gap between the electrode 108 and the nozzle 110, thereby generating a pilot arc in the gap. To complete the pilot arc circuit, the pilot arc current path 752 can return to the torch head 102 by flowing proximally from the nozzle 110 to the swirl ring 150 (which can be made of a conductive material) and to the current ring 800 in the torch head 102. As shown, the distal end of the swirl ring 150 physically contacts the nozzle 110 at the interface 758. The proximal end of the swirl ring 150 physically contacts at least the distal edge 802 of the ring portion 800a of the current ring 800 via the Louvertac electrical connector 756. Therefore, the swirl ring 150 is configured to return the pilot arc current 752 from the nozzle 110 of the barrel 104 to the torch head 102. The loop portion 800a of the current loop 800 may transfer the arc pilot current 752 to the raised portion 800b of the current loop 800, which transfers the arc pilot current 752 to the arc pilot current connection 124 within the cavity 148 to return the arc pilot current to the power source.

[0111] The gas flow in the gap between the electrode 108 and the nozzle 110 is ionized by the pilot arc so that the resistance between the electrode 108 and the workpiece (not shown) becomes smaller. A voltage higher than the voltage used to initiate the pilot arc can be applied across the electrode 108 and the workpiece to cause the arc to transfer to the workpiece after the gap is ionized. This arc between the electrode 108 and the workpiece is a transferred arc. In order to maintain the transferred arc, a higher voltage transferred arc current supplied from the power supply is transferred from the cathode 130 to the electrode 108 via the coolant tube 116 and the Louvertac rings 702, 704 in a manner generally similar to the distal pilot arc current 752. In order to complete the transferred arc circuit, the transferred arc current is returned from the workpiece to the power supply via a separate line (not shown).

[0112] b. Communication device (RFID reader)

[0113] On the other hand, the torch insulator 118 can be configured to support wireless communication between the torch head 102 and the barrel 104. In some embodiments, the torch insulator 118 includes a cavity 114 ( Figure 2 ), which has an opening 144a ( Figure 3 ). The cavity 144 can be configured to retain the communication device 122 within the torch insulator 118. The communication device 122 can be removed from the cavity 144 via the opening 144a. In some embodiments, the cavity 144 extends partially into the torch insulator 118 along the central longitudinal axis A so that there is no corresponding opening on the distal end 23 of the torch insulator 118.

[0114] Fig.10 1 is an exemplary design of a communication device 122 of a torch head 102 according to an exemplary embodiment of the present invention. The communication device 122 may include a radio frequency identification (RFID) reader adapted to receive a signal from a device located at the barrel 104 ( Figure 2 The communication device 122 is adapted to process the signals to retrieve relevant data about the barrel 104 (and / or other torch information) transmitted by the signal device 160, and forward the data to a processor (not shown) for analysis. Generally, the communication device 122 may be placed at a location in the plasma arc torch 10, such as in the torch insulator 118, to minimize the likelihood that the plasma arc and arc ignition will interfere with wireless communication between the signal device 160 and the communication device 122. The communication device 122 may include a connector 806 at a proximal end thereof, an antenna assembly 808 at a distal end thereof, and a processing assembly 810 between the connector 806 and the antenna assembly 808.

[0115] The antenna assembly 808 may include an antenna coil 814 configured to wirelessly transmit an RF signal to the signal device 160 to interrogate the signal device 160, and / or receive an RF signal from the signal device 160 in response to the interrogation. The antenna coil 814 may be located at the distal end of the antenna assembly 808 (i.e., the distal end of the communication device 122) so that when the communication device 122 is inserted into the cavity 144, the antenna coil 814 is embedded in the distal end 23 of the torch insulator 118. This placement minimizes the wireless communication distance between the antenna coil 814 and the signal device 160 in the barrel 104, and reduces communication interference therebetween. In some embodiments, the antenna coil 814 is positioned at the end face of the distal end of the communication device. For example, the antenna coil 814 may be wound around the post 812 at the distal end of the antenna assembly 808. The assembly 808 may also include a plastic cylindrical housing configured to feed one or more wires connected to the antenna coil 814 to the processing assembly 810. The processing assembly 810 may include a plastic cylindrical housing having one or more hardware components (e.g., a printed circuit board (PCB)) disposed therein. The PCB connected to the line from the antenna coil 814 of the antenna assembly 808 is configured to (i) provide power to the communication device 122 including the antenna assembly 808, (ii) provide power to the signal device 160, and / or (iii) wirelessly communicate with the signal device 160 via the antenna coil 814 using a communication protocol (e.g., an RFID protocol such as ISO / IEC 15693) to process data from the signal device 160. In some embodiments, the PCB can provide power to the entire torch communication circuit on the welding torch 10 (including the communication device 122, the signal device 160, and related components). The connector 806 electrically connected to the PCB of the processing assembly 810 is configured to transmit data processed by the processing assembly 810 to a computing device (e.g., a central processing unit, etc.) outside the welding torch 10. For example, the connector 806 cooperating with the PCB of the processing assembly 810 can transmit information obtained from the signal device 160 to an external computing device using a wireless or wired connection.

[0116] In some embodiments, the circuitry that allows wireless communication between the communication device 122 and the signal device 160 is analog, while the circuitry that allows communication (wired or wireless) between the communication device 122 and an external computing device is digital. In this configuration, placing the communication device 122 including the PCB into the welding torch 10 reduces the communication distance between the communication device 122 and the signal device 160, and thus reduces noise pickup in the corresponding analog circuitry. However, placing the communication device 122 into the welding torch 10 may extend the communication distance between the communication device 122 and the remote computing device, and thus may increase noise pickup in the corresponding digital circuitry, but digital circuitry is more robust (i.e., more immune) to noise pickup than analog circuitry.

[0117] In some embodiments, the communication device 122 is surrounded by one or more layers of a protective material that, for example, provides electrical insulation, liquid coolant leak protection (plus protection from waste conveyed by the coolant flow), and protection from other environmental factors. In some embodiments, the housing of the processing assembly 810 and / or the housing of the antenna assembly 808 are made of a durable plastic to protect the components therein from liquids and debris. The housing may be translucent so that the LED signals of the PCB therein may be visible from outside the housing. In some embodiments, one or more O-ring seals are used to protect the communication device 122 from liquid damage and create an electrical insulation layer.

[0118] In some embodiments, the communication device 122 in the torch insulator 118 is electrically isolated from the plasma power and ignition circuits, such as by an electrical isolation of approximately 30,000 V. In some embodiments, the communication device 122 is configured to fit within the torch insulator 118 while accommodating all of the other components of the torch insulator 118 described above, as well as a protective layer surrounding the communication device 122, which adds to its volume. For example, the communication device 122 can be designed to be long, thin, and / or flexible to better fit within the torch insulator 118.

[0119] During operation, the plasma arc torch 100 may cause up to 100 degrees Celsius in ambient temperature, which leaves little margin for operating temperature rise. Therefore, in some embodiments, the communication device 122 is designed to generate a minimum operating temperature. For example, the communication device 122 may have a low circuit power voltage, a low multi-point control unit (MCU) clock frequency, a low operating duty cycle, and / or a sleep mode for minimizing heating when not in operation.

[0120] In some embodiments, the torch communication circuit, including the communication device 122 and the signal device 160, is offset from the central longitudinal axis A of the plasma arc torch 10. This offset allows the communication circuit to be away from the area of ​​the torch that defines the plasma processing performance. In general, the area where the communication circuit is located is less susceptible to changes in the plasma process design, which allows for design freedom of the plasma process, as well as stability in the performance of the communication circuit. In some embodiments, to reduce unwanted coupling between the torch communication circuit and nearby metal components, the size of the antenna coil 814 is minimized (e.g., reducing the diameter of the coil), and / or the RFID power is minimized to reduce the size of the resulting RFID field. In general, adjacent metal components that may couple with the RFID field can be taken into account and the size and proximity with respect to the torch communication circuit are kept roughly consistent.

[0121] In alternative embodiments, the plasma arc torch 10 does not include a communication system (which includes, for example, a communication device 122 in the torch head 102 or a signaling device 106 in the barrel 104). For example, the communication device may not be present in the torch, where the barrel 104 is connected to the torch head 102 or a quick disconnect torch head, which in turn is connected to the torch housing.

[0122] In some embodiments, Figure 2 and 10 As shown in , the communication system of the plasma arc torch 10 also includes a second signal device 162 (e.g., an RFID tag) disposed in or on the communication device 122 in the torch insulator 118, such as in the antenna assembly 808 of the communication device 122 proximate the antenna coil 814. Alternatively, the second signal device 162 can be located in the torch head 102 outside the communication device 122 and / or the torch insulator 118. An optional base 164 can be used to hold the second signal device 162 in place. The second signal device 162 is configured to read and / or write information about the plasma arc torch 10 (e.g., the number of arcs ignited) and transmit the information to the plasma cutting system, which can then relay the information to the first signal device 160 in the barrel 104. In general, the first signal device 160 and the second signal device 162 can transfer information back and forth between them.

[0123] c. Ohmic contact

[0124] On the other hand, the torch insulator 118 can be configured to support ohmic contact for the purpose of controlling the relative height between the welding torch 10 and the workpiece to facilitate torch operation. In some embodiments, the torch insulator 118 includes an ohmic contact cavity 146 ( Figure 8 ), which has an opening 146a ( Figure 3 ). Figure 8 oriented to show an exemplary ohmic contact path 780 according to an exemplary embodiment of the present invention. Figure 2 1. As shown, the ohmic contact cavity 146 of the torch insulator 118 in the torch head 102 can be configured to hold the ohmic contact connection 131, which can be connected through the opening 146a ( Figure 3 ) is removed from the cavity 146. In some embodiments, the ohmic contact cavity 146 extends partially into the torch insulator 118 along the longitudinal axis A so that there is no corresponding opening on the distal end 23 of the torch insulator 118.

[0125] Figure 8The ohmic contact path 780 allows a controller (not shown) of the welding torch 10 to detect and sense the workpiece / plate 782 for the purpose of controlling the relative height between the welding torch 10 and the workpiece / plate 782 before or during operation of the welding torch. With respect to the ohmic contact path 780, when the welding torch head 102 is installed during operation of the welding torch, the incoming pin (not shown) makes electrical contact with the ohmic contact connection 131 to form the electrical contact path 780. The path 780 then continues through the length of the ohmic contact connection 131 to electrically contact the welding torch body 18 via the adjustment screw 784. The path 780 travels distally over the welding torch body 18 and the retaining cap 120 to reach the shield 114 of the barrel 104. The path 780 allows the controller to sense the position of the workpiece / plate 782 and adjust the relative height accordingly. In some embodiments, the shroud 114 of the barrel 104 is electrically isolated from the nozzle 110 of the barrel 104 to allow an ohmic contact path 780 to travel from the torch head 102 to the shroud 114 on the outer surface of the welding torch 10 .

[0126] In some embodiments, Figure 8 The ohmic contact path 780 in the embodiment is electrically isolated from the pilot arc current path 752 and / or the transferred arc current path by using the torch insulator 118. For example, the pilot arc current path 752 and the transferred arc current path may pass through the torch insulator 118 while the ohmic contact path 780 passes primarily through the torch body 18.

[0127] d. Protective gas

[0128] On the other hand, the torch insulator 118 can be configured to direct one or more gas flows from the torch head 102 to the barrel 104. In some embodiments, the torch insulator 118 is configured to direct at least one shield gas from the torch head 102 to the barrel 104. Exemplary shield gases include air, oxygen (i.e., O2), and argon. In some embodiments, the shield gas flow paths and passages described herein are also compatible with a shield fluid, such as water, between the torch head 102 and the barrel 104. The torch insulator 118 may include an opening 126a ( Figure 3 ) extends to the shield gas opening 126b (shown in FIG. 1 ) at the distal end 23 of the torch insulator 118. Figure 4 Shielding gas channel 850 (shown in FIG. 8 ).

[0129] 11a and b are diagrams oriented to illustrate an exemplary shield gas flow path 868 from the torch head 102 to the barrel 104 on the shield gas passage 850 (including shield gas passage segments 850a and 850c) according to an exemplary embodiment of the present invention. Figure 21. A cross-sectional view of a plasma arc torch 10. As shown, the shielding gas passage 850 may include several segments. A first passage segment 850a connects the opening 126a on the proximal end 21 of the torch insulator 118 to an internal opening 860 in or on the insulator 118. The first passage segment 850a may extend generally parallel to the longitudinal axis A. A second passage segment (not shown) may connect the opening 860 to another internal opening 862 in or on the insulator 118, wherein the second internal opening 862 is radially offset from the first internal opening 860. For example, the internal openings 860, 862 may be radially offset by approximately 30 degrees to approximately 90 degrees. The second passage segment may extend circumferentially (or in different orientations) around the torch insulator 118 to connect the internal openings 860, 862. A third passage segment 850c connects the internal opening 862 to the opening 126b on the distal end 23 of the torch insulator 118. The third channel segment 850c can extend substantially parallel to the longitudinal axis A.

[0130] In some embodiments, when the barrel 104 is attached to the torch head 102, the corresponding shielding gas channel 864 in the barrel frame 112 of the barrel 104 is fluidly aligned with the shielding gas channel segment 850c. The shielding gas flow 868 can enter the barrel 104 via the proximal opening 864a of the shielding gas channel 864 in the barrel frame 112. The shielding gas channel 864 also has an opening 864b at the distal end of the barrel frame 112, which is fluidly connected to the gas passage 872 between the shield 114 and the nozzle 110. Therefore, the shielding gas channel 864 can introduce shielding gas from the torch head 102 into the gas passage 872. In some embodiments, the barrel frame 112 includes one or more components in the path of the shielding gas channel 864 to adjust one or more parameters (e.g., flow pattern and flow rate) of the shielding gas flow 868 therein. Details about the shielding gas channel 864, the vortex component of the barrel frame 112, and the shielding gas flow 868 passing through the barrel 104 are described below.

[0131] 11a and b, shield gas is introduced into the torch head 102 via the shield gas opening 126a at the proximal end 21 of the torch insulator 118. The gas 868 flows distally through the shield gas channel segment 850a to the internal opening 860. The gas 868 can then flow circumferentially (or in a different orientation) around the torch insulator 118 via a second segment of the shield gas channel 850 to reach the internal opening 862 spaced apart from the internal opening 860. The gas 868 flows longitudinally from the opening 862 via the shield gas channel segment 850c to the opening 126b on the distal end 23 of the torch insulator 118 to the barrel 104. Upon exiting the torch head 102 via the opening 126b, the shield gas flow 868 enters the shield gas channel 864 of the barrel frame 112 in the barrel 104. Gas 868 flows distally through shield gas passage 864 of cartridge frame 112 and out of opening 864b of shield gas passage 864 to gas passage 872 between shroud 114 and nozzle 110 to cool both components. Shield gas 868 is adapted to flow out of cartridge 104 via shroud outflow aperture 870.

[0132] e. Plasma gas

[0133] In some embodiments, the torch insulator 118 of the torch head 102 can direct one or more plasma gases from the torch head 102 to the barrel 104. For example, the torch insulator 118 can be configured to receive multiple gas sources, select a gas or a mixture of gases, and introduce the selected gas or gas mixture into the barrel 104. Figures 12a-c are oriented to show an exemplary plasma gas flow path 900 from the torch head 102 to the barrel 104 according to an exemplary embodiment of the present invention. Figure 2 1. A cross-sectional view of a plasma arc torch 10.

[0134] The torch insulator 118 includes two plasma gas openings 200a and 200b at the proximal end 21 of the torch insulator 118, wherein each opening is configured to receive a plasma gas, such as oxygen (O2), air, nitrogen (N2), a hydrogen-based gas (e.g., H35), F5 fuel gas, or a mixture of one or more of these chemicals. In addition, the torch insulator 118 may include a cavity 202 (shown in Figures 12a-c) configured to receive a plasma gas valve 204. The cavity 202 is connected to the opening 202a ( Figure 3 12a-c) via which a plasma gas valve 204 is removably disposed in the chamber 202. The plasma gas valve 204 is configured to select one or a mixture of gases received from the plasma gas openings 200a and 200b and to direct the resulting gas or gas mixture over the plasma gas passage 206 (shown in FIGS. 12a-c) and through the opening 200c (also shown in FIG. 12c) on the distal end 23 of the torch insulator 118. Figure 4 ) is introduced into the barrel 104.

[0135] As shown in FIG12a, the exemplary plasma gas flow path 900 includes a first plasma gas flow 900a introduced from a plasma gas opening 200a via a connecting passage 902 into a plasma gas valve 204 located in the chamber 202. The connecting passage 902 fluidly connects the opening 200a with an inlet 904 of the plasma gas valve 204 to introduce the first plasma gas flow 902 into the valve 204. As shown in FIG12b, the plasma gas flow path 900 includes a second plasma gas flow 900b introduced from a plasma gas opening 200b into the plasma gas valve 204 via a connecting passage 906. The connecting passage 906 fluidly connects the opening 200b with a second inlet 908 for introducing the second plasma gas flow 900b into the plasma gas valve 204. 12c, the plasma gas valve 204 selects a gas or a mixture of gases and transmits the resulting plasma gas flow 900c on the plasma gas passage 206 to flow out of the opening 200c at the distal end 23 of the torch insulator 118. The plasma gas passage 206 is adapted to extend longitudinally along the length of the torch 10 and fluidly connect the outlet 910 of the plasma gas valve 204 to the opening 200c at the distal end 23 of the torch insulator 118.

[0136] With respect to the plasma gas flow path 900c shown in FIG. 12c, upon exiting the torch head 102 via the opening 200c, the plasma gas flow 900c enters the corresponding plasma gas passage 912 of the barrel frame 112 in the barrel 104 via the opening 912a on the proximal end 15 of the barrel frame 112. The gas 900c flows longitudinally through the plasma gas passage 912 of the barrel frame 112 and exits from the opening 912b at the distal end 17 of the barrel frame 112, which introduces the gas into the plasma gas passage 918 between the electrode 108 and the nozzle 110 of the barrel 104. The plasma gas 900c is adapted to flow distally through the passage 918 and out of the barrel 104 via the central nozzle outflow orifice 916 and the central shield outflow orifice 870. In some embodiments, the swirl ring 150 in the path of the plasma gas flow 900c may introduce a swirling motion into the plasma gas flow 900c. Details regarding the plasma gas passage 912, the swirl ring 150, and the plasma gas flow 900c through the barrel 104 are described below.

[0137] In some embodiments, the shield gas flow 868 and the plasma gas flow 900 are fluidly isolated from each other in both the torch head 102 and the barrel 104 so that the gases do not cross paths or share the same passage. For example, the plasma gas passage 206 and the shield gas passage 850 are fluidly isolated from each other. In some embodiments, the torch insulator 118 of the torch head 102 is configured to control the gas flow through the welding torch 10 by directing the shield gas flow 868 and the plasma gas flow 900 to appropriate passages within the barrel frame 112 for distribution to appropriate gas passages in the barrel 104 (e.g., passage 872 between the shield 114 and the nozzle 110 for the shield gas flow 868, and passage 918 between the nozzle 110 and the electrode 108 for the plasma gas flow 900c).

[0138] f. Liquid coolant flow

[0139] On the other hand, the torch insulator 118 can be configured to direct a series of liquid coolant flows to circulate between the torch head 102 and the barrel 104. Exemplary liquid coolants include water, propylene glycol, ethylene glycol, or any number of commercially available coolants specifically designed for use in plasma cutting systems. Figure 3 As shown in FIG. 1 , the torch insulator 118 may include a coolant opening 128 a at the proximal end 21 of the torch insulator 118 for introducing liquid coolant into the torch head 102 .

[0140] 13a and b are diagrams of an exemplary liquid coolant flow path 950 oriented to show circulation between the torch head 102 and the barrel 104 in a series of flow segments according to an exemplary embodiment of the present invention. Figure 213a, the liquid coolant is first introduced into the torch head 102 via the opening 128a at the proximal end 21 of the torch insulator 118. The coolant 950 flows from the opening 128a to the cathode block 606 in the torch insulator 118 on the connecting passage 952, and enters the cathode block 606 via at least one inlet of the cathode block 606. FIGS. 14a and 14b are exemplary profile views and proximal views of the cathode block 606 of the torch head 102 according to an exemplary embodiment of the present invention, respectively. As shown in FIG. 14b, the cathode block 606 may include a first group of three liquid inlets 620a-c dispersed around the inner circumference of the cathode block 606. In other embodiments, more or fewer inlets are defined. The connecting passage 952 fluidly connects the torch insulator opening 128a to the first group of liquid inlets 620a-c to conduct the coolant into the cathode block 606. The liquid inlets 620a-c of the cathode block 606 may also conduct liquid coolant to the openings 745 at the proximal ends 740 of the coolant tubes 116, which may be physically attached to the cathode block 606 as described above. In some embodiments, the connections between the inlets 620a-c and the openings 745 at the proximal ends of the coolant tubes 116 are cross-connected (e.g., for space-saving purposes) to deliver coolant from the cathode block 606 to the coolant tubes 116.

[0141] Once in the coolant tube 116, the coolant flow path 950 continues longitudinally toward the distal end 742 of the coolant tube 116. The coolant flow 950 flows out of the coolant tube 116 through the distal opening 746 of the coolant tube 116 and into the cavity 954 defined by the inner surface of the electrode 108 of the barrel 104, thereby generally cooling the electrode 108. Thus, the initial coolant flow path 950 is generally defined within the main channel 132 of the torch insulator 118 (which receives at least a portion of the coolant tube 116 and the cathode 130) and the corresponding main channel 1020 of the barrel frame 112 (which is connected to the cavity 954 of the electrode 108). When guided by the wall of the cavity 954, the coolant flow 950 reverses direction and continues proximally in the main channels 1020, 132 along the outer surface of the coolant tube 116. This counterflow also generally cools the Louvertac ring 704 surrounding the outer portion of the distal end 742 of the coolant tube 116 .

[0142] The coolant flow 950 continues toward the cathode block 606 of the torch head 102. The coolant flow 950 may enter the cathode block 606 via the distal opening 622 (shown in FIG. 14a ) of the cathode block 606. Once within the cathode block 606, the coolant 950 flows radially outward on the outflow channel 624 of the cathode 130. The outflow channel 624 fluidly connects the cathode 606 to a first coolant channel 958 of the torch insulator 118, which extends longitudinally along the length of the torch head 102 to conduct the coolant flow 950 from the torch head 102 to the barrel 104 again. Specifically, the first coolant channel 958 fluidly connects the outflow channel 624 to a first liquid coolant opening 960a (also at the distal end 23 of the torch insulator 118) on the torch insulator 118. Figure 4 The first coolant passage 958 conducts the coolant flow 950 from the cathode 130 to the barrel 104 via the opening 960a of the torch insulator 118, and introduces the coolant flow 950 into the opening 962a of the proximal end 15 of the barrel frame 112, wherein the proximal opening 962a is connected to the corresponding first coolant passage 962 of the barrel frame 112 in the barrel 104.

[0143] The coolant 950 flows distally through the cartridge frame 112 on the first coolant passage 962 to the opening 962b at the distal end 17 of the cartridge frame 112, which fluidly connects the first coolant passage 962 of the cartridge frame 112 to the nozzle opening 966 associated with the nozzle 110. Specifically, the nozzle 110 may be coupled to the outer nozzle member 111 (e.g., a nozzle jacket for a non-discharge nozzle and a nozzle bushing for a discharge nozzle), and the opening 966 may be on the outer nozzle member 111 so that it can direct the coolant flow from the distal coolant passage opening 962b into the nozzle coolant flow chamber 965 between the outer surface of the nozzle 110 and the inner surface of the outer nozzle member 111. As the coolant flow 950 is conducted distally through the nozzle coolant flow chamber 965 via the nozzle opening 966, it generally cools the nozzle 110 and the outer nozzle member 111. Upon reaching the distal tip of the nozzle 110, the coolant flow 950 may swirl around at least a portion of the circumference of the nozzle 110 via a circumferential channel (not shown) disposed on the outer surface of the nozzle 110. The coolant flow 950 may return proximally to a different side of the nozzle 110 within the flow chamber 965 and toward another opening 967 on the outer nozzle member 111. The second nozzle opening 967 is in turn fluidly connected to a second coolant channel 968 of the barrel frame 112. Specifically, the second coolant channel 968 interfaces with the second opening 967 of the outer nozzle member 111 at an opening 968b at the distal end 17 of the barrel frame 112. The second coolant channel 968 of the barrel frame 112 is adapted to conduct the liquid coolant flow 950 away from the nozzle coolant flow chamber 965 and through the second liquid coolant channel opening 968a on the proximal end 15 of the barrel frame 112 and the second liquid coolant channel opening 960b (also at the distal end 23 of the torch insulator 118) at the distal end 23 of the torch insulator 118. Figure 4 102) into a corresponding second coolant passage 970 of the torch insulator 118 of the torch head 102. As the coolant flow 950 travels proximally within the second coolant passage 970 of the torch head 102 through the torch insulator 118, the coolant flow encounters an interior opening 972 of the second coolant passage 970 in the torch insulator 118. That is, the second coolant passage 970 connects the interior opening 972 with the opening 960b on the distal end 23 of the torch insulator 118.

[0144] As shown in FIG. 13b, the inner opening 972 of the second coolant passage 970 can be fluidly connected to the inner opening 974 of the third coolant passage 976 of the torch insulator 118 via a distribution channel (not shown) extending circumferentially around the torch insulator 118. The second coolant passage 970 and the third coolant passage 976 can be radially offset from each other by about 30 degrees to about 90 degrees (e.g., 70 degrees). Therefore, the distribution channel connects the inner openings 972, 974 to deliver the coolant flow 950 from the second coolant passage 970 to the third coolant passage 976. Within the third coolant passage 976, the coolant 950 flows toward the third coolant passage opening 960c (also at the distal end 23 of the torch insulator 118) on the distal end 23 of the torch insulator 118. Figure 4 14, and 15. The coolant flow 950 is shown in FIG. 14 and is shown in FIG. 14 ... Along the circumferential shroud coolant flow region 1222, the coolant flow 950 can return to the barrel frame 112 on a different side of the flow region 1222 by entering the opening 982b at the distal end 17 of the barrel frame 112. The opening 982b in fluid communication with the shroud coolant flow region 1222 is connected to the fourth coolant passage 982 of the barrel frame 112. The coolant flow 950 then travels proximally in the fourth coolant passage 982, flows out of the fourth coolant passage 982 through the opening 982a at the proximal end 15 of the barrel frame 112, and flows into the torch head 102. The coolant flow 950 flows through the fourth coolant passage opening 960d (also at the distal end 23 of the torch insulator 118) at the distal end 23 of the torch insulator 118. Figure 4 ) into the torch head 102. The opening 960d at the distal end 23 of the torch insulator 118 is fluidly connected to a fourth coolant passage 984 of the torch insulator 118, which is configured to deliver the coolant flow 950 from the barrel 104 to an internal opening 986 in the torch insulator 118, which is fluidly connected to the cathode block 606.

[0145] As shown in FIGS. 14a and 14b, the cathode block 606 includes a second set of one or more liquid inlets 626 extending from an outer surface to an inner surface of the cathode block 606. In some embodiments, the cathode block 606 includes a second set of three liquid inlets 626a-c dispersed around the outer circumference of the cathode block 606. In other embodiments, more or fewer inlets are defined. Referring to FIG. 13b, a connecting passage 988 fluidly connects an inner opening 986 of a fourth coolant passage 984 of the torch insulator 118 to the second set of liquid inlets 626a-c to conduct the coolant 950 from the fourth coolant passage 984 to the cathode block 606. In some embodiments, the connection between the second set of inlets 626a-c and the inner opening 986 is cross-connected (e.g., for space saving purposes) to deliver the coolant from the fourth coolant passage 984 to the cathode block 606 in a swirling manner. Once within the cathode block 606 , the coolant flow 950 continues to flow proximally out of the torch insulator 118 through the cathode tube 604 and the cathode assembly 602 , in that order.

[0146] In some embodiments of the torch insulator 118, the first coolant passage 958 and the second coolant passage 970 may be radially offset from each other by approximately 30 to 90 degrees (e.g., approximately 90 degrees). The third coolant passage 976 and the fourth coolant passage 984 may be radially offset from each other by approximately 30 to 90 degrees (e.g., approximately 90 degrees). In some embodiments of the barrel frame 112, the first coolant passage 962 and the second coolant passage 968 may be radially offset from each other by the same degree (e.g., approximately 90 degrees) as the offset between the first coolant passage 958 and the second coolant passage 970 of the torch insulator 118. The third coolant passage 978 and the fourth coolant passage 982 may be radially offset from each other by the same degree (e.g., approximately 90 degrees) as the offset between the fourth coolant passage 984 and the third coolant passage 976 of the torch insulator 118. In some embodiments of the plasma arc torch 10, the second coolant passages 970, 968 are radially offset from the third coolant passages 976, 978 by approximately 30 degrees to approximately 90 degrees (eg, 70 degrees).

[0147] In general, as described above with reference to FIGS. 13a and b, the torch insulator 118 of the torch head 102, in cooperation with the barrel frame 112 of the barrel 104, is configured to control the coolant flow 950 entering and exiting the torch head 102 and barrel 104 for distribution to various components at the barrel tip. For example, the torch insulator 118 and barrel frame 112 may direct the coolant flow 950 in the following order: (i) from the cathode 600 to the coolant tube 116, and in the reverse direction in the main channel 132 of the torch insulator 118 and the main channel 1020 of the barrel frame 112 to cool the electrode 108, wherein each main channel 132, 1020 serves as both a supply channel and a return channel; (ii) from the first coolant channel 958 (i.e., the supply channel) of the torch insulator 118, to the first coolant channel 962 (i.e., the supply channel) of the barrel 104, to (iii) from a third coolant passage 976 (i.e., supply passage) of the torch insulator 118, to a third coolant passage 978 (i.e., supply passage) of the barrel 104, to a fourth coolant passage 982 (i.e., return passage) of the barrel 104, and to a fourth coolant passage 984 (i.e., return passage) of the torch insulator 118 to cool the shroud 114. In an alternative embodiment, the coolant flow 950 includes only one of the three sets of supply and return passages to cool one barrel tip component. In an alternative embodiment, the coolant flow 950 includes two of the three sets of supply and return passages to cool two barrel tip components.

[0148] Even though the coolant flow paths 950 of FIGS. 13 a and b are shown in the order of cooling the electrode 108, followed by the nozzle 110, and then the shroud 114 at the barrel tip, other cooling orders are equally applicable. For example, a different order may include cooling the shroud 114, followed by the nozzle 110, and then the electrode 108. Yet another order may include cooling the nozzle 110, followed by the shroud 114, and then the electrode 108. In some embodiments, any order of cooling these three components of the barrel tip is contemplated by the present invention.

[0149] In some embodiments, the shield gas flow path 868, the plasma gas flow path 900, and the coolant flow path 950 are fluidly isolated from each other in both the torch head 102 and the barrel 104 so that these fluids do not cross paths and do not share the same channels. In some embodiments, the shield gas flow path 868, the plasma gas flow path 900, and the coolant flow path 950 are predefined based on synchronization of the torch head 102 with the barrel 104 in a predetermined orientation. This synchronization feature will be described in detail below. In some embodiments of the torch insulator 118, one or more of the coolant channels 968, 970, 976, 984, the plasma gas channel 206, and the shield gas channel 850 are non-concentric with respect to the central longitudinal axis A. One or more of the arc-maintaining connector cavity 148, the communication device cavity 144, and the plasma gas valve cavity 202 are non-concentric with respect to the central longitudinal axis A. In the torch insulator 118 ( Figure 3 In some embodiments (shown in ), one or more of the opening 202a for receiving the plasma gas valve 204, the plasma gas openings 200a, 200b, the cavity opening 148a for receiving the pilot arc connection 123, the liquid coolant opening 128a, the cavity opening 146a for receiving the ohmic connection 131, the shielding gas opening 126a, the cavity opening 144a for receiving the communication device 122, and the main passage opening 132a are disposed on the end surface of the proximal end 21 of the torch insulator 118, where the end surface may be substantially flat. These openings other than the main passage opening 132a may be disposed on the proximal end surface non-concentrically relative to the central longitudinal axis A. On the torch insulator 118 ( Figure 4 In some embodiments (shown in ), one or more of the plasma gas opening 200c, the liquid coolant openings 960a-d and the shielding gas openings 126, the main passage opening 132b are disposed on the end surface of the distal end 23 of the torch insulator 118, where the end surface may be substantially flat. These openings, except the main passage opening 132a, may be disposed on the distal end surface non-concentrically relative to the central longitudinal axis A. In the context of the present invention, "non-concentric" means that the available channels, cavities, or openings are offset with respect to the longitudinal axis A. In some embodiments, each non-concentric channel, cavity, or opening is oriented asymmetrically relative to the longitudinal axis A.

[0150] In some embodiments, the main passage opening 132a at the proximal end 21 of the torch insulator 118, the main passage 132, and the main passage opening 132b at the distal end 23 of the torch insulator 118 are centrally located and concentrically disposed relative to the central longitudinal axis A. As described above, the main passage 132 is configured to provide at least one of (i) a pilot arc or a transferred arc current or (ii) at least a portion of a liquid coolant flow 950 from the torch head to the barrel.

[0151] Interface between torch head and barrel

[0152] Reference Figure 4 The distal end 23 of the torch insulator 118 may also include a synchronization feature 220 (eg, a pin) configured to secure the torch insulator 118 to the barrel frame 112 in a predetermined radial orientation when engaged between the torch head 102 and the barrel 104 . Fig.15 1 is a view of the proximal end 15 of the cartridge frame 112 according to an exemplary embodiment of the present invention. The proximal end 15 of the cartridge frame 112 may include a synchronization feature (e.g., a pin cavity) 1002, which may interact with a corresponding synchronization feature 220 on the distal end 23 of the torch insulator 118 to form an interface 106 ( Figure 2 This interface 106 allows alignment of the various electrical, liquid coolant, and gas passages between the torch head 102 and the barrel 104, thereby maintaining the above reference Figure 7 , 8 and 11a-13b as described in the predefined electrical, liquid coolant and gas flow paths. In some embodiments, the end surface of the distal end 23 of the torch insulator 118 is substantially flat. The end surface of the proximal end 15 of the barrel frame 112 can also be substantially flat, so that the interface 106 therebetween is substantially flat.

[0153] With respect to the continuity of coolant flow between the torch head 102 and the barrel 104, when the torch insulator 118 is synchronized with the barrel frame 112 in a predetermined radial orientation, the first liquid coolant passage opening 960a ( Figure 4 13a) is aligned with the first coolant passage opening 962a (shown in FIGS. 13a and 15) at the proximal end 15 of the cartridge frame 112 to fluidly connect the first liquid coolant passage 958 of the torch insulator 118 with the first liquid coolant passage 962 (shown in FIG. 13a) of the cartridge frame 112. In the same predetermined radial orientation, the second liquid coolant passage opening 960b (shown in FIG. 13a) of the torch insulator 118 is aligned with the first coolant passage opening 962a (shown in FIGS. 13a and 15) at the proximal end 15 of the cartridge frame 112 to fluidly connect the first liquid coolant passage 958 of the torch insulator 118 with the first liquid coolant passage 962 (shown in FIG. 13a) of the cartridge frame 112. Figure 4 13a) is aligned with the second coolant passage opening 968a (shown in FIGS. 13a and 15) at the proximal end 15 of the cartridge frame 112 to fluidly connect the second coolant passage 970 of the torch insulator 118 with the second coolant passage 968 (shown in FIG. 13a) of the cartridge frame 112. In the same predetermined radial orientation, the third liquid coolant passage opening 960c ( Figure 413b) is aligned with the third coolant passage opening 978a (shown in FIGS. 13b and 15) at the proximal end 15 of the cartridge frame 112 to fluidly connect the third coolant passage 976 of the coolant insulator 118 with the third coolant passage 978 (shown in FIG. 13b) of the cartridge frame 112. In the same predetermined radial orientation, the fourth liquid coolant passage opening 960d ( Figure 4 13b) is aligned with the fourth coolant channel opening 982a (shown in FIGS. 13b and 15) of the cartridge frame 112 so that the fourth coolant channel 984 of the coolant insulator 118 is fluidly connected with the fourth coolant channel 982 (shown in FIG. 13b) of the cartridge frame 112.

[0154] The shield gas openings 126b ( 126c ) on the distal end 23 of the torch insulator 118 are oriented in a predetermined radial direction relative to the continuity of gas flow between the torch head 102 and the barrel 104. Figure 4 11b) is aligned with the shield gas opening 864a (shown in FIGS. 11b and 15) at the proximal end 15 of the barrel frame 112 to fluidly connect the third shield gas passage segment 850c of the torch insulator 118 with the shield gas passage 864 (shown in FIG. 11b) of the barrel frame 112. In the same predetermined radial orientation, the plasma gas opening 200c ( Figure 4 and 12c) is aligned with the plasma gas proximal opening 912a (shown in Figures 12c and 15) at the proximal end 15 of the barrel frame 112 so that the plasma gas passage 206 of the welding torch insulator 118 is fluidly connected with the plasma gas passage 912 (shown in Figure 12c) of the barrel frame 118.

[0155] With respect to data communication between the torch head 102 and the barrel 104, the reading device 122 and the signaling device 160 are rotationally aligned in a predetermined radial orientation permitted by the synchronization features 220, 1002. For example, the antenna coil 814 embedded in the torch insulator 118 can be mapped to the region 230 ( Figure 4 ), which has a center 232 that coincides with a center 1018 ( Fig.15 ), which maps to the signal device 160 embedded in the cartridge 104. This rotational alignment between the centers 232, 1018 reduces communication interference between the reading device 122 and the signal device 160.

[0156] Fig.31 According to an exemplary embodiment of the present invention Figure 21 is a portion of a plasma arc torch 10, which shows exemplary positions of the communication device 122 and the signal device 160 when the torch head 102 and the barrel 104 are in a predetermined radial orientation with respect to each other. In some embodiments, in the aligned position, the distance 816 between the longitudinal and radial centers of the antenna coil 814 and the longitudinal and radial centers of the signal device 160 is less than the distance between the longitudinal and radial centers of the signal device 160 and any adjacent metal material disposed in the torch head 102 or the barrel 104. In some embodiments, the RFID field generated by the antenna coil 814 is a torus shape around the perimeter of the disc-shaped RFID tag 160. The cross-section of the torus field at any point is circular. To prevent interference, the distance between the RFID tag 160 and the reading device 122 along the x-axis (measured at the center point of the circular cross-section of the field) is smaller or closer than the distance between the RFID tag 160 and any adjacent metal along the y-axis. Therefore, when the RFID field moves in a circular path around the torus shape, the field is configured so that it does not encounter any metal before encountering the RFID tag 160. In some embodiments, in the aligned position, the signal device 160 and the reader device 122 are oriented such that a linear axis extends through a centerline of the signal device 160 and a centerline of the reader device 122. In some embodiments, the antenna coil 814 of the reader device 122 is oriented substantially parallel to the signal device 160. In some embodiments, the antenna coil 814 and the RFID tag 160 communicate at a frequency of approximately 13.5 MHz.

[0157] Compared to Figure 2102 and the barrel 104, when the torch insulator 118 is docked with the barrel frame 112, the distal opening 132b of the main channel 132 of the torch insulator 118 is adapted to be aligned with the opening 1020a at the proximal end 15 of the barrel frame 112 to be connected to the main channel 1020 of the barrel frame 112. Therefore, the distal end 742 of the coolant tube 116 is adapted to be inserted into the main channel 1020 of the barrel frame 112 via the opening 1020a. The opening 1020b of the main channel 1020 at the distal end 17 of the barrel frame 112 is connected to the cavity 954 of the electrode 108, so that the coolant tube 116 extends through the opening 1020b and extends into the cavity 954. As described above, the pilot arc current and / or the transferred arc current from the power source may be sent from the cathode 130 of the torch head 102 to the coolant tube 116, both attached to the torch insulator 118, and to the electrode 108 of the barrel 104 via the inner surface of the electrode cavity 954. The coolant tube 116, which carries the current, thus excites the inner surface of the electrode 108. In some embodiments, one or more Louvertac rings 702, 704 on one or both ends 740, 742 of the coolant tube 116 are used to facilitate conducting electricity from the power source to the inner surface of the electrode 108. The use of at least the Louvertac ring 704 at the distal end 742 of the coolant tube 116 radially aligns / centers the electrode 108 with respect to the coolant tube 116, but does not attach the electrode 108 to any particular radial orientation. For example, during assembly, the operator may apply an axial force to push the electrode 108 proximally against the coolant tube 116 until the Louvertac ring 704 at the distal end 742 of the coolant tube 116 is completely within the lumen 954 of the electrode 108 and is covered by a majority of the lumen 954. Thus, the Louvertac ring 704 of the coolant tube 116 allows the electrode 108 to be pushed up or pulled down axially during engagement or disengagement, respectively, without the use of threading (or other synchronized movement), thereby allowing the use of a tool-free and / or thread-free electrode 108.

[0158] The simple push-on / pull-off feature is also compatible with the engagement between the synchronization feature 220 of the torch insulator 118 and the synchronization feature 1002 of the barrel frame 112 to form the interface 106. That is, the coupling between the torch head 102 and the barrel 104 can be managed by the synchronization features 220, 1002 without having to address any threaded or other synchronization requirements between the electrode 108 and the coolant tube 116. In general, allowing the coolant tube 116 and the Louvertac ring 704 to deliver the pilot arc / transferred arc current to the barrel 104 separates (i) the physical interface between the torch insulator 118 and the barrel frame 112 from (ii) the electrical connection between the cathode 130 / coolant tube 116 and the electrode 108. This separation is suitable for maximizing design space and simplifying torch assembly. In addition, the relatively direct axial installation and removal of the coolant tube 116 (and therefore the torch head 102) and the electrode 108 (and therefore the barrel 104) promotes faster consumable replacement and installation. Furthermore, due to the placement of the Louvertac ring 704 with respect to the coolant tube 116 (e.g., on the outer surface of the coolant tube 116), the Louvertac ring 704 can be easily inspected and easily maintained. In alternative embodiments, instead of using the Louvertac ring 704, other current transmission features and / or retention features can be used, such as threaded attachment, interference fit, etc.

[0159] In some embodiments, since the cutting current is transmitted from the power source to the electrode 108 by the coolant tube 116, the electrode 108 does not need to be in direct electrical or physical contact with the torch head 102 for current transfer purposes. In some embodiments, the electrode 108 is electrically isolated from the torch head 102 by the cathode block electrode tube 252, which connects the electrode 108 to the cathode 130 and the coolant tube 116. The cathode block electrode tube 252 can be made of a non-conductive material such as plastic. On the other hand, the electrode 108 is shorter than an electrode for directly receiving current from the cathode. In this example, since the electrode 108 does not physically or electrically contact the cathode 130, the electrode 108 can be shorter than a directly contacting electrode, such as more than 25% shorter.

[0160] When the coolant tube 116 is axially inserted into the cavity 954 of the electrode 108 and the torch insulator 118 is radially synchronized with the barrel frame 112 (e.g., by inserting the synchronization pin 220 of the torch insulator 118 into the synchronization pin cavity / receiver 1002 of the barrel frame 112), the barrel 104 can be retained against the torch head 102 using the retaining cap 120 (shown in FIG. 1). Other methods of engagement between the torch head 102 and the barrel 104 are possible, including threaded, snap fit, interference fit, etc. Fig.161 is a cross-sectional view of an exemplary design of the retaining cap 120 of FIG. 1 for securing the barrel 104 and the torch head 102 to each other according to an exemplary embodiment of the present invention. The retaining cap 120 includes a body 764 extending along a longitudinal axis A, a proximal end 760, and a distal end 762. The proximal end 760 of the retaining cap body 764 includes an engagement feature 766 (e.g., a groove, a thread, or a step) disposed circumferentially on the inner surface to capture the torch head 102 against the retaining cap body 764. Similarly, the distal end 762 of the retaining cap body 764 includes an engagement feature 768 (e.g., a groove, a thread, or a step) disposed on the inner surface to capture the barrel 104 against the retaining cap body 764. Thus, when the barrel 104 is synchronized with the torch head 102, the retaining cap 102 can securely and circumferentially surround the outer surface of the torch head 102 at the distal end 22 of the torch head 102 and the outer surface of the barrel 14 at the proximal end 104 of the barrel 104. In some embodiments, the torch head 102 and / or the barrel are not rotated relative to the retaining cap 120. In this example, the operator can slide the retaining cap 120 on the barrel 104 and / or the torch head 102 to lock the parts without using any rotational movement. In some embodiments, the retaining cap 120 is provided as a part of the torch head 102. In some embodiments, the retaining cap 120 is provided as a part of the barrel 104. In some embodiments, the retaining cap 120 is provided as a different component separate from the barrel 104 or the torch head 102.

[0161] cylinder

[0162] Fig.17 1 is a cross-sectional view of the barrel 104 of FIG. 1 according to an exemplary embodiment of the present invention, wherein the barrel 104 is a non-discharge barrel. As described above, the barrel 104 may generally include a barrel frame 112 coupled to a barrel tip, the barrel tip including an electrode 108, a nozzle 110 of a non-discharge nozzle attached to a nozzle jacket 111, and a shroud 114. The barrel frame 112 is adapted to form an interface between the barrel tip and the torch head 102, thereby connecting the barrel tip to the torch head 102. Various components of the barrel 104, including the barrel frame 112, the electrode 108, the nozzle 110, the nozzle jacket 111, and the shroud 114 may be concentrically arranged around the longitudinal axis A of the plasma arc torch 10. In some embodiments, the barrel 104 includes a plurality of retaining features that allow components of the barrel tip to align and engage with one or more channels in the barrel frame 112, so that these channels can conduct liquids and gases from the torch head 102 through the barrel frame 112 and to the desired components in the barrel tip. In some embodiments, the proximal end 14 of the cartridge 104, including the proximal end 15 of the cartridge frame 112, is substantially flat.

[0163] In general, the various components of the cartridge tip may be secured directly or indirectly to the cartridge frame 112 while achieving axial alignment and radial alignment (i.e., centering) relative to the cartridge frame 112. The electrode 108 may be secured to the cartridge frame 112, wherein at least a portion of the electrode 108 is disposed in the central channel 1020 of the cartridge frame 112. In some embodiments, the electrode 108 is secured to the cartridge frame 112 via a swirl ring 150 that surrounds at least a portion of the main channel 1020. Specifically, the outer diameter of the electrode 108 may be secured to the inner diameter of the swirl ring 150 such that at least the proximal portion of the electrode 108 is inserted into the distal portion of the swirl ring 150. If the swirl ring 150 is conductive, the swirl ring 150 may be secured to the electrode 108 via an electrode insulator 754. As shown, the electrode 108 includes an outer retaining feature 1066 on the outer surface (e.g., one or more steps of varying diameter of the electrode 108) that is configured to matingly engage an inner retaining feature 1068 on the inner surface of the electrode insulator 754 (e.g., one or more complementary steps or protrusions) to prevent axial movement of the electrode 108 and the electrode insulator 754 relative to each other. The match between the retaining features 1066, 1068 can be one of a snap fit, a press fit, or an interference fit. The resulting interface 1067 between the electrode 108 and the electrode insulator 754 also aligns / centers the two components radially. The electrode insulator 754, in turn, includes an outer retaining feature 1056 on the outer surface (e.g., a step of varying diameter of the electrode insulator 754) to matingly engage an inner retaining feature 1054 on the inner surface of the swirl ring 150 (e.g., a complementary step or protrusion) to prevent axial movement of the electrode insulator 754 and the swirl ring 150 relative to each other. The match between the retaining features 1054, 1056 may be one of a snap fit, a press fit, or an interference fit. The resulting interface 1055 between the electrode insulator 754 and the swirl ring 150 also aligns / centers the two components radially. If the swirl ring 150 is substantially non-conductive, the swirl ring 150 may be directly secured to the electrode 108 without the electrode insulator 754. In some embodiments, the outer diameter of the swirl ring 150 matches the inner diameter of the cartridge frame 112 to couple the electrode 108 to the cartridge frame 112. For example, the swirl ring 150 may be secured to the cartridge frame 112 by matching the outer retaining features 1052 on the outer surface (e.g., a step of varying diameter of the swirl ring 150) with the inner retaining features 1058 on the inner surface of the cartridge frame 112 (e.g., a complementary step or protrusion) to prevent the swirl ring 150 and the cartridge frame 112 from axially moving relative to each other. The match between the retaining features 1052, 1058 may be one of a snap fit, a press fit, or an interference fit.The resulting interface 1053 between the scroll ring 150 and the cartridge frame 112 also radially aligns / centers the two components.

[0164] The nozzle 110 and the nozzle jacket 111 may be engaged between the swirl ring 150 and the cartridge frame 112. In some embodiments, the outer diameter of the swirl ring 150 is engaged to the inner diameter of the nozzle 110. The swirl ring 150 may be secured to the nozzle 110 by matching an outer retaining feature 1050 on the outer surface (e.g., one or more steps of varying diameter of the swirl ring 150) with an inner retaining feature 1060 on the inner surface of the nozzle 110 (e.g., a complementary step or protrusion) to prevent axial movement of the swirl ring 150 and the nozzle 110 relative to each other. The match between the retaining features 1050, 1060 may be one of a snap fit, a press fit, or an interference fit. The resulting interface 1051 between the swirl ring 150 and the nozzle 110 also radially aligns / centers the two components. In some embodiments, the outer diameter of the nozzle 110 is secured to the inner diameter of the cartridge frame 112. The nozzle 110 can be secured to the cartridge frame 112 by matingly engaging at least one outer retaining feature 1070 on the outer surface (e.g., one or more steps of varying diameter of the nozzle 110) with at least one inner retaining feature 1072 (one or more complementary steps or protrusions) on the inner surface of the cartridge frame 112 to prevent axial movement of the nozzle 110 and the cartridge frame 112 relative to each other. The match between the retaining features 1070, 1072 can be one of a snap fit, a press fit, or an interference fit. The resulting interface 1071 between the nozzle 110 and the cartridge frame 112 also aligns / centers the two components radially.

[0165] The shield 114 can be coupled to the outer surface of the barrel frame 112. For example, the outer diameter of the barrel frame 112 is fixed to the inner diameter of the shield 114 by matching the outer retaining features 1062 (e.g., the steps of the changing diameter of the barrel frame 112) on the outer surface of the barrel frame 112 with the inner retaining features 1064 (e.g., complementary steps or protrusions) on the inner surface of the shield 114 to prevent the barrel frame 112 and the shield 114 from axial movement relative to each other. The match between the retaining features 1062, 1064 can be one of a snap fit, a press fit, or an interference fit. The resulting interface 1063 between the barrel frame 112 and the shield 114 aligns / centers the two components radially. In addition, the barrel frame 112 may include a recess 1065 on the outer surface configured to receive the distal portion of the shield 114 by crimping, thereby further fixing and aligning the shield 114 to the barrel frame 112.

[0166] In some embodiments, the above-mentioned retaining features 1050-1072 can be matched with their corresponding retaining features by one of snap fit, press fit, interference fit, crimping, friction fit, gluing, cement joint or welding. In some embodiments, the retaining features 1050-1072 include one or more sealing O-rings or gaskets made of, for example, hardened epoxy or rubber. In some embodiments, the retaining features 1050-1072 allow the nozzle 110, jacket 111, shield 114 and / or electrode 108 of the barrel tip to align and engage with one or more channels in the barrel frame 112, so that these channels can conduct liquid and / or gas from the welding torch head 102 through the barrel frame 112 and to the desired components in the barrel tip. The liquid and gas connection between the barrel frame 112 and the barrel tip is described in detail below.

[0167] Fig.18 According to an exemplary embodiment of the present invention Fig.17 104 of the cartridge 104. The cartridge frame 112 includes a generally cylindrical insulating body 1100 disposed between the torch head 102 and the cartridge tip. More specifically, the insulating body 1100 includes an inner region 1106, an outer surface 1108, an inner surface 1110 surrounding and forming a main channel 1020, a proximal end 15 having an end surface 1102, and a distal end 17 having an end surface 1104. Fig.15 The proximal end 15 of the barrel frame 112 includes a central opening 1020a for receiving an electrical current and / or coolant flow 950 from the coolant tube 116 of the torch head 102, a plasma gas opening 912a for receiving a plasma gas flow 900c from the torch insulator 118, a shield gas opening 864a for receiving a shield gas flow 868 from the torch insulator 118, and four liquid coolant openings 968a, 978a, 962a, and 982a for conducting a liquid coolant flow 950 into and out of the barrel 104. In some embodiments, these openings are disposed on an end face 1102 of the proximal end 15 of the insulator body 1100. In some embodiments, the end face 1102 is substantially coplanar with the proximal end 14 of the barrel 104. Generally, these openings are configured to be electrically and / or fluidically connected to their corresponding openings on the distal end 23 of the torch insulator 118 when the torch head 102 is aligned with and connected to the barrel 104 in a predetermined orientation via the synchronization features 1002 of the barrel frame 112 and the corresponding synchronization features 220 of the torch insulator 118.

[0168] Electrical connections in the barrel

[0169] In some embodiments, the electrode 108 is aligned with and connected to a main channel 1020 disposed in the insulating body 1100 of the cartridge frame 112. The channel 1020 may be disposed in the center of the insulating body 110 with the central longitudinal axis A extending therethrough to connect an opening 1020a on the end surface 1102 of the proximal end 15 of the cartridge frame 112 to an opening 1020b on the end surface 1104 of the distal end 17 of the cartridge frame 112. The distal opening 1020b is in turn connected to the electrode 108 ( Figure 2 102 ). As described above, this electrode interface allows the coolant tube 116 to be inserted into the main channel 1020 to transfer current (i.e., pilot arc or transferred arc current) from the cathode 130 of the torch head 102 to the inner surface of the electrode 108. In this case, as described above, the electrode 108 can be electrically isolated from the cathode 130. In an alternative embodiment, the electrode 108 is electrically connected to the cathode 130 to receive current directly from the cathode 130. In some embodiments, the same electrode interface (i.e., between the electrode 108 and the torch head 102, via the main channel 1020 of the barrel frame 112) can allow the torch head 102 to introduce liquid coolant from the inside of the coolant tube 116 into the electrode 118. This liquid coolant conduction feature of the main channel 1020 of the barrel frame 112 is discussed in detail below.

[0170] Fig.19 According to an exemplary embodiment of the present invention Fig.17104 of the embodiment of the present invention. The radioactive insert 1200 may be disposed in the distal end 1202 of the electrode 108 so as to expose the radiation surface. The insert 1200 may be made of hafnium or other materials having suitable physical characteristics, including corrosion resistance and high thermal electron emission. Forging, impact extrusion or cold forming may be used to first form the electrode 108 before finishing the component. The proximal end 1204 of the electrode 108 may be disposed in and aligned with the main channel 1020 of the barrel frame 112 via the distal opening 1020b of the barrel frame 112. The electrode 108 may be connected to the barrel frame 112 using at least a swirl ring 150 and an electrode insulator 754. In some embodiments, the electrode 108 does not include any threads for connecting to the electrode insulator 754 or the swirl ring 150. As described above, this connection may be performed by one of a press fit, an interference fit, a crimping or a snap fit. In some embodiments, the electrode 108 is shorter than an electrode for receiving current directly from the cathode 130 (i.e., without using the coolant tube 116). In these cases, since the electrode 108 does not need to physically or electrically contact the cathode 130, the electrode 108 can be shorter than a directly contacting electrode, e.g., more than 25% shorter. In some embodiments, the electrode 108 includes an O-ring groove 1205 at the proximal end 1204, wherein the O-ring groove 1205 is configured to receive an O-ring, which can be used to seal the plasma chamber or chamber 109 cooperatively defined by the electrode 108 and the nozzle 110. This seal prevents the plasma gas flow 900c from being separated from the electrode 108 and the electrode insulator 754 ( Fig.17 ) between the

[0171] Shielding gas connection in the cylinder

[0172] In some embodiments, the shielding gas passage 872 formed between the shield 114 and the nozzle jacket 111 is aligned with the shielding gas channel 864 (shown in Figures 11a and b) disposed in the insulating body 1100 of the cartridge frame 112. The shielding gas channel 864 (shown in Figures 11a and b) may extend substantially parallel to the longitudinal axis A in the interior region 1106 of the insulating body 1100, but offset from the central longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The shielding gas channel 864 connects the opening 864a on the end face 1102 at the proximal end 15 of the cartridge frame 112 to the opening 864b at the distal end 17 of the cartridge frame 112. In some embodiments, the opening 864b is disposed on the end face 1104 at the distal end 17 of the cartridge frame 112. In an alternative embodiment, the opening 864b of the shielding gas passage 864 distal to the opening 864a along the longitudinal axis A is disposed on the outer side surface 1108 or the inner side surface 1110 of the barrel frame body 110 (i.e., the passage 864 does not extend through the entire length of the body 1100 in the longitudinal direction). The opening 864b is in turn fluidly connected to the shielding gas passage 872, which allows the shielding gas flow 868 to pass from the torch head 102 through the barrel frame 112 of the barrel 104 and pass into the shielding gas passage 872 (shown in Figures 11a and b). In some embodiments, the shielding gas passage 864 may be configured to provide a metering function to the shielding gas flow 868 therein. For example, the diameter of the shielding gas passage 864 may vary over the length of the passage to provide a metering function. The diameter of the shielding gas passage 864 at the distal end 17 of the barrel frame 112 may be approximately half the diameter of the shielding gas passage 864 at the proximal end 15 of the barrel frame 112 to reduce the flow rate of the shielding gas flow 868.

[0173] In some embodiments, the cartridge frame 112 includes one or more components in the path of the shield gas passage 864 to adjust one or more properties of the shield gas flow 868 therein. For example, the cartridge frame 112 may include an adjustment component, such as a two-piece component including a baffle 1112 and a shield swirl ring 1114. Fig.17 As shown in , the baffle 1112 and the shield swirl ring 1114 are circumferentially disposed within the insulating body 1100 of the cartridge frame 112 at its distal end 17, and the two components are in the path of the shield gas passage opening 864b so that they adjust certain flow parameters and introduce swirl motion into the shield gas flow 868 as it flows out of the cartridge frame 112 and enters the shield gas passage 872. The use of these two separate components 1112, 1114 provides manufacturing and assembly advantages when the operator can use different combinations of baffles and shield swirl rings to form different types of shield gas flows.

[0174] Fig. 20 For attachment to an exemplary embodiment of the present invention Fig.17104 of the cartridge 104. In some embodiments, at least one of the baffle 1112 or the shield swirl ring 1114 is made of a non-conductive material, such as Torlon™. In some embodiments, at least one of the baffle 1112 or the shield swirl ring 1114 is made of a conductive material. The baffle 1112 and the shield swirl ring 1114 can be independently manufactured by molding, stamping, or die casting.

[0175] As shown, the baffle 1112 is located near the shield swirl ring 1114 so that when the shield airflow 868 travels distally, it is first regulated by the baffle 1112 and then by the shield swirl ring 1114. In other embodiments, the positions of the baffle 1112 and the shield swirl ring 1114 are reversed. The baffle 1112 can be circumferentially arranged in the insulating body 1100 of the barrel frame 112, such as in the cavity 1116 at the distal end 17 of the insulating body 1100. The baffle 1112 can be fixed to the cavity 1116 by one of an interference fit or a press fit. The baffle 1112 includes a longitudinal portion 1118 and a radial portion 1120, which is connected to the longitudinal portion 1118 at an angle so that the radial portion 1120 covers a portion of the width 1122 of the cavity 1116, but leaves a radial gap 1124 between the outer diameter of the radial portion 1120 and the inner surface of the cavity 1116. The shield gas flow 868 within the shield gas passage 864 is adapted to be dispersed by the baffle 1112 to flow uniformly through the radial gap 1124 around its outer diameter and into the swirl ring 1114. The shape and size of the radial gap 1124 are determined to adjust at least one parameter of the shield gas flow 868. For example, the radial gap 1124 can adjust the flow rate and / or fluid pressure of the shield gas flow 868. In some embodiments, increasing the size of the radial gap 1124 increases the flow rate of the shield gas flow 868, in which case the plasma arc torch system can be adjusted accordingly to maintain a constant pressure. In some embodiments, increasing the size of the radial gap 1124 reduces the gas pressure, in which case the plasma arc torch system can be adjusted accordingly to maintain a constant flow rate.

[0176] The shield scroll ring 1114 may be inserted into at least a portion of the cavity 1116 by at least one of an interference fit or a press fit such that it is distal with respect to the baffle 1112 . Fig.211 is a cross-sectional view of a shield swirl ring 1114 according to an exemplary embodiment of the present invention. The shield swirl ring 1114 may define a first set of ports 1126 around a first circumference of the swirl ring 1114 and a second set of ports 1128 around a second circumference of the swirl ring 1114, wherein each port connects the inner surface of the barrel frame 112 to the outer surface of the barrel frame 112. The first set of ports 1126 is offset from its corresponding one in the second set of ports 1128. This offset imparts a swirling motion to the shield gas flow 868 passing therethrough. Therefore, the combination between the baffle 1112 and the shield swirl ring 1114 can adjust the parameters of the shield gas flow 868 as it travels distally through the shield gas passage 864 to the shield gas passage 872. In general, the shield gas flow 868 in the plasma arc torch 10 can be constructed by changing the size of the gap 1124 of the baffle and / or the size of the first set of ports 1126 and the second set of ports 1128 in the shield swirl ring 1114.

[0177] Plasma gas connection in the cylinder

[0178] In some embodiments, the plasma gas passage 918 formed between the electrode 108 and the nozzle 110 is aligned with the plasma gas channel 912 (shown in Figures 12a-c) disposed in the insulating body 1100 of the cartridge frame 112. The plasma gas channel 912 (shown in Figures 12a-c) may extend substantially parallel to the longitudinal axis A in the interior region 1106 of the insulating body 1100, but deviate from the longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The plasma gas channel 912 connects the opening 912a on the proximal surface 1102 at the proximal end 15 of the cartridge frame 112 to the opening 912b. In some embodiments, the opening 912b of the plasma gas channel 912 distal to the opening 912a along the longitudinal axis A is disposed on the inner surface 1110 of the cartridge frame body 1100 and is in fluid communication with the central channel 1020. Therefore, in this configuration, the plasma gas channel 912 does not extend along the entire length of the cartridge frame body 1100 in the longitudinal direction.

[0179] Fig. 221 is a perspective view of a cartridge frame 112 according to an exemplary embodiment of the present invention, showing various channel openings, including an opening 912b of a plasma gas channel 912. As shown, the opening 912b is on the inner side surface 1110 in the central region of the cartridge frame 112, and the opening 912b is fluidly connected to the central channel 1020. In an alternative embodiment, the plasma gas channel 912 extends over the entire length of the cartridge frame 112, wherein the opening 912b is located on the distal end surface 1104 of the cartridge frame insulating body 1100. The opening 912b is fluidly connected to the plasma gas passage 918. This connection allows the plasma gas flow 900c to pass from the torch head 102 through the cartridge frame 112 and into the plasma gas passage 918, which merges into the central main channel 1020 before the plasma gas flow 900c flows out of the welding torch 10 via the central nozzle outflow orifice 916 and the central shield outflow orifice 870 (shown in Figures 12a-c).

[0180] In some embodiments, the cartridge frame 112 includes one or more components in the path of the plasma gas channel 912 configured to adjust one or more properties of the plasma gas flow 900c therein. For example, the cartridge frame 112 may include a swirl ring 150 circumferentially located between the nozzle 110 and the electrode insulator 754 around the main channel 1020. The swirl ring 150 may be aligned with the distal plasma gas channel opening 912b so that the swirl ring 150 may introduce a swirling motion into the plasma gas flow 900c as it flows out of the plasma gas channel 912 through the opening 912b on the inner side surface 1110 of the cartridge frame 112 and into the plasma gas passage 918.

[0181] Fig.23 According to an exemplary embodiment of the present invention Fig.17 104. As shown, the swirl ring 150 may be defined by a generally hollow elongated body 1170 having a proximal end 1174 and a distal end 1172 along a central longitudinal axis A of the plasma arc torch 10. In some embodiments, the hollow body 1170 of the swirl ring 102 at the distal end 1172 is sized to directly or indirectly receive at least a portion of the electrode 104 via the electrode insulator 754. In some embodiments, the swirl ring 150 includes a set of radially spaced gas flow openings 1176 disposed about the distal end 1172 of the elongated body 1170, e.g., about the circumference of the distal end 1172 thereof. Each gas flow opening 1176 can extend from the inner surface to the outer surface of the elongated body 1170 and be oriented to impart a tangential velocity component to the plasma gas flow 900c traveling in the gas passage 918 between the electrode 108 and the nozzle 110, thereby causing a vortex in the gas flow 900c. The vortex causes a swirl that shrinks the plasma arc and stabilizes the position of the arc on the insert 1200 of the electrode 108.

[0182] Coolant connection in cartridge

[0183] In some embodiments, as described above, components of the barrel tip (e.g., electrode 108, nozzle 110, or shroud 114) may be aligned with at least one cooling channel (e.g., channel 1002, 962, or 978) and at least one coolant return channel (channel 1002, 968, or 982) in the insulating body 1100 of the barrel frame 112 to receive a liquid coolant flow from the torch head 102 and return at least a portion of the fluid flow to the torch head 102, respectively. Each of the cooling channels and return channels, except for the main channel 1002, may be non-concentric with respect to the central longitudinal axis A and asymmetric about the longitudinal axis A. In some embodiments, except for the main channel 1002, no cooling channels and return channels overlap. That is, except for the main channel 1002, each of the cooling channels and return channels is a liquid inlet channel or a liquid outlet channel.

[0184] In some embodiments, the central passage 1020 extends through the insulating body 1100 of the cartridge frame 112 to connect its opening 1020a on the end face 1102 at the proximal end 15 of the cartridge frame 112 to its opening 1020b at the distal end 17 of the cartridge frame 112. The proximal opening 1020a is aligned with and connected to the main passage opening 132b of the torch insulator 118. The distal opening 1020b is aligned with and connected to the cavity 954 of the electrode 108, which allows the coolant flow 950 to pass from the torch head 102 through the cartridge frame 112 and into the cavity 954 of the electrode 108 while within the coolant tube 116 (shown in Figures 13a and b). This connection also allows the coolant flow 950 to impinge on the inner surface of the distal end of the cavity 954 so that the coolant flow 950 can be reversed and travel proximally through the main channel 1020 (shown in Figures 13a and b) along the outer surface of the coolant tube 116 toward the torch head 102. This reverse coolant flow on the outer surface of the coolant tube 116 also generally cools the Louvertac ring 704 attached to the distal end 742 of the coolant tube 116. In some embodiments, the reverse coolant flow can travel through the longitudinal channel 744 on the outer surface of the coolant tube 116 below the Louvertac ring 704, thereby limiting the pressure drop between the coolant tube 116 and the electrode 108.

[0185] In some embodiments, a nozzle opening 966 formed on the nozzle jacket 111 is aligned with a first coolant channel 962 (shown in FIGS. 13a and b) disposed in the insulating body 1100 of the cartridge frame 112. The nozzle opening 966 allows the coolant flow 950 to enter the nozzle coolant flow chamber 965 between the outer surface of the nozzle 110 and the inner surface of the nozzle jacket 111 from the first coolant channel 962. The first coolant channel 962 (shown in FIGS. 13a and b) may extend substantially parallel to the longitudinal axis A in the interior region 1106 of the insulating body 1100, but offset from the longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The first coolant channel 962 may connect an opening 962a on the end surface 1102 at the proximal end 15 of the cartridge frame 112 to an opening 962b of the cartridge frame 112, which is distal to the opening 962a along the longitudinal axis A. The opening 962b is in turn fluidly connected to the nozzle opening 966, which allows the coolant flow 950 to travel distally from the torch head 102, through the barrel frame 112 of the barrel 104, and into the nozzle coolant flow chamber 965 (shown in Figures 13a and b).

[0186] In some embodiments, the opening 962b of the first coolant passage 962 is disposed on the inner side surface 1110 of the cartridge frame body 1100 and is in fluid communication with the central passage 1020. Therefore, in this configuration, the first coolant passage 962 does not extend over the entire length of the cartridge frame body 1100 in the longitudinal direction. Fig. 22 , the opening 962b of the first coolant passage 962 is shown. As shown, the opening 962b is on the inner side surface 1110 toward the distal end 17 of the barrel frame 112, and the opening 962b is fluidly connected to the central channel 1020. In an alternative embodiment, the first coolant passage 962 extends over the entire length of the barrel frame 112, wherein the opening 962b is located on the distal end face 1104 of the barrel frame insulating body 1100. The opening 962b is fluidly connected to the nozzle opening 966 in the nozzle jacket 111. This connection allows the liquid coolant flow 950 to pass from the torch head 102 through the barrel frame 112 and enter the nozzle coolant flow chamber 965 between the nozzle 110 and the nozzle jacket 111 to cool the two nozzle components.

[0187] As described above, the nozzle opening 966 is configured to align with the first coolant passage 962 of the cartridge frame 112, so that the coolant flow 950 can be introduced from the first coolant passage 962 into the nozzle coolant flow chamber 965 via the nozzle opening 966. The nozzle opening 966 can be in fluid communication with a second nozzle opening 967 on the nozzle jacket 111, wherein the two coolant openings 966, 967 are radially offset from each other (i.e., on different sides of the nozzle 110). The coolant flow 950 can enter the nozzle coolant flow chamber 965 via the nozzle opening 966, flow through the flow chamber 965 proximally, return distally on different sides of the chamber 965, and flow out of the chamber 965 via the second opening 967. In some embodiments, the second opening 967 is aligned with and connected to a second coolant passage 968 (FIGS. 13a and b) disposed in the cartridge frame 112. The second coolant passage 968 may extend substantially parallel to the longitudinal axis A within the interior region 1106 of the insulating body 1100, but offset from the longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The second coolant passage 968 connects the opening 968a on the end face 1102 at the proximal end 15 of the barrel frame 112 to the opening 968b at the distal end 17 of the barrel frame 112, which in turn connects to the second nozzle opening 967. This connection allows the coolant flow 950 to travel proximally from the nozzle coolant chamber 965 through the barrel frame 112 of the barrel 104 and into the torch head 102 (shown in Figures 13a and b). In some embodiments, the opening 968b of the second coolant passage 968 distal to the opening 968a along the longitudinal axis A is disposed on the inner side surface 1110 of the barrel frame body 1100. Thus, the first coolant passage 962 and the second coolant passage 968 cooperating with the nozzle openings 966 , 967 allow the coolant flow 950 to cool the nozzle 110 and the nozzle jacket 111 via the nozzle coolant flow chamber 965 .

[0188] 24a and 24b are respectively Fig.17 1 and 12. An external view of a non-discharge nozzle 110 with a nozzle jacket 111. The non-discharge nozzle 110 includes a proximal end / portion 1206, a middle portion 1208, and a distal end / portion 1210 along the longitudinal axis A of the welding torch 10. The distal end 1210 of the nozzle 108 includes a centrally located nozzle outflow orifice 916 for directing a plasma arc, such as an ionized gas jet, into a workpiece to be cut (not shown). The nozzle jacket 111 includes a generally hollow body 1212 defining a proximal end 1214 and a distal end 1216 along the longitudinal axis A. The nozzle 110 is adapted to be inserted into the hollow body 1212 of the nozzle jacket 111 such that the distal end 1210 of the nozzle 108 extends through an opening in the distal end 1216 of the nozzle jacket 111.

[0189] In some embodiments, the nozzle jacket 111 includes nozzle openings 966, 967 at a proximal end 1214 thereof, wherein each opening connects an outer surface to an inner surface of the nozzle jacket body 1212. The openings 966, 967 may be oriented on generally opposite sides of the nozzle jacket 111 (e.g., approximately 180 degrees from each other). In some embodiments, an outer surface of a middle portion 1208 of the nozzle 111 and a corresponding inner surface of the nozzle jacket 111 cooperatively define a nozzle coolant flow chamber 965. The flow chamber 965 may be located generally in the middle of the nozzle 110 and the nozzle jacket 111 along the longitudinal axis A, and / or at its widest radial section. In some embodiments, the distal portion 1210 of the nozzle 110 includes a circumferential flow channel 1218 around the nozzle 110 (i.e., a flow channel extending approximately 360 degrees around the nozzle 110) located through an opening at the distal end 1216 of the nozzle jacket 111. The circumferential channel 1218 allows coolant to flow through the outer surface of the tip of the nozzle 110 , thereby promoting convective cooling of the nozzle tip and reducing stagnation of the flowing liquid during torch operation. The circumferential flow channel 1218 may be at least partially defined by the curved surface of the nozzle 110 .

[0190] In operation, the cooling liquid flow 950 may enter the flow chamber 965 through the opening 966 on one side of the nozzle jacket 111. The cooling liquid flow 950 may travel distally in the longitudinal direction toward the circumferential flow channel 1218 on one side of the flow chamber 965. Upon reaching the circumferential flow channel 1218, the coolant flow 950 may swirl around the nozzle tip and return proximally on the other side of the nozzle 110 that is generally opposite (e.g., approximately 180 degrees) to the distal flow. The return flow 950 may flow out of the nozzle coolant flow chamber 965 through the opening 967 to the barrel frame 112.

[0191] In some embodiments, the inner surface of the shield 114 is fluidly connected to the third coolant channel 978 (shown in Figures 13a and b) disposed in the insulating body 1100 of the cartridge frame 112. The third coolant channel 978 may extend substantially parallel to the longitudinal axis A in the inner region 1106 of the insulating body 1100, but deviate from the longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The third coolant channel 978 may connect the opening 978a on the end face 1102 at the proximal end 15 of the cartridge frame 112 to the opening 978b in the cartridge frame 112, which is distal to the opening 978a along the longitudinal axis A. In some embodiments, the opening 978b of the third coolant channel 978 is disposed on the outer side surface 1108 of the cartridge frame body 1100. Therefore, in this configuration, the third coolant channel 978 does not extend over the entire length of the cartridge frame body 1100 in the longitudinal direction. Fig. 2213 a and b).

[0192] In such Fig. 22 In some embodiments shown in , the outer side surface 1108 of the middle section of the cartridge frame 112 defines a circumferential flow channel 1220 around the cartridge frame 112 (i.e., a flow channel extending about 360 degrees around the cartridge frame 112). The circumferential channel 1220 is fluidically connected to the opening 978b of the third coolant channel 978. The circumferential channel 1220 cooperating with the inner circumference of the shroud 114 forms a shroud coolant flow region 1222 (shown in FIG. 13 b), which allows the coolant flow 950 to flow therethrough, thereby cooling the inner circumference of the shroud 114. In some embodiments, the circumferential channel 1220 is fluidly connected to the opening 982b of the fourth coolant channel 982 of the cartridge frame 112, which may also be located on the outer side surface 1108 of the cartridge frame 112. The opening 982b is distal to the opening 982a along the longitudinal axis A. The openings 978b, 982b may be radially offset with respect to each other, for example, 180 degrees, so they are on opposite sides of the cartridge frame 112. The fourth coolant passage 982 may extend generally parallel to the longitudinal axis A, but offset from the longitudinal axis A (i.e., non-concentric with respect to the longitudinal axis A). The fourth coolant passage 982 is adapted to connect the opening 982a on the end surface 1102 at the proximal end 15 of the cartridge frame 112 to the opening 982b.

[0193] In operation, the coolant flow 950 may travel distally to the shroud 114 via the opening 978b of the third coolant passage 978. Upon entering the shroud coolant flow region 1222 (i.e., defined by the circumferential flow channels 1220 on the outer side surface 1108 of the barrel frame 112 and the corresponding inner circumference of the shroud 114), the coolant flow 950 may swirl around the shroud coolant flow region 1222 and return proximally on the other side of the shroud coolant flow region 1222 that is substantially opposite (e.g., approximately 180 degrees) to the distal flow. The return flow 950 may flow out of the shroud coolant flow region 1222 to the barrel frame 112 via the opening 982b of the fourth coolant passage 982.

[0194] Fig.25 According to an exemplary embodiment of the present invention Fig.17104. The shield 114 includes a generally hollow body including a centrally located shield outflow orifice 870 and one or more gas exhaust holes (not shown) that optionally extend from the inner surface to the outer surface of the shield 114. The shield 114 may be cold formed or stamped using copper.

[0195] In general, relative to the proximal end 15 of the barrel frame 112, the first coolant passage opening 962a can function as a coolant inlet for the nozzle 110, the second coolant passage opening 968a can function as a coolant outlet for the nozzle 110, the third coolant passage opening 978a can function as a coolant inlet for the shroud 114, and the fourth coolant passage opening 982a can function as a coolant outlet for the shroud 114. In some embodiments, when the torch head 102 is coupled to the barrel 104, the second coolant passage opening 968a, which functions as a coolant outlet for the nozzle 110, is fluidly connected to the third coolant passage opening 978a, which functions as a coolant inlet for the shroud 114. Specifically, as described above with reference to FIGS. 13a and b, the distribution channel in the torch insulator 118 connecting the internal openings 972, 974 of the torch insulator 118 can direct the coolant flow 950 from the second coolant passage 968 to the third coolant passage 978 to cool both the nozzle and the shroud.

[0196] In some embodiments, one or more of the liquid coolant channel openings 962a, 968a, 978a, 982a, the plasma gas channel opening 912a, the shield gas channel opening 864a, and the main channel opening 1020a are disposed on the end surface 1102 of the proximal end 21 of the torch insulator 118, where the end surface may be substantially flat. Except for the main channel opening 1020a, these openings may be disposed non-concentrically on the proximal end surface 1102 relative to the central longitudinal axis A. In some embodiments, one or more of the coolant channels 962, 968, 978, 982, the plasma gas channel 912, and the shield gas channel 864 of the barrel frame 112 are non-concentric relative to the central longitudinal axis A.

[0197] RFID communication in the cartridge

[0198] In some embodiments, the cartridge frame 112 forms a communication interface (eg, an RFID communication interface) between the torch head 102 and the cartridge tip. Fig.17, the insulative body 1100 of the cartridge frame includes an RFID mounting feature 1230 formed on or in the cartridge frame 112 near the end face 1102 of the proximal end 15 of the cartridge frame 112. For example, the mounting feature 1230 may be a cavity disposed in the cartridge frame body 1110 from the end face 1102. The RFID mounting feature 1230 (e.g., cavity) may be disposed in the interior region 1106 of the cartridge frame 112 and may be positioned / oriented in a non-concentric manner with respect to the central longitudinal axis A.

[0199] The signal device 160 may be disposed in or on the mounting feature 1230 to transmit information about the cartridge 104 (e.g., about the electrode 108, the nozzle 110, the shield 114, and / or the cartridge frame 112 itself) to an adjacent reading device, such as the communication device 122 in the torch insulator 118 when the torch head 102 is coupled to the cartridge 104. For example, the signal device 160 may be embedded in the cavity 1230 and surrounded by the insulating material of the cartridge frame body 1100. The signal device 160 may be an RFID tag that can be written and / or read electrically. Exemplary information encoded on the signal device 160 may include general or fixed information, such as the name, brand, manufacturer, serial number, and / or type of the component. In some embodiments, the encoded information is unique to the component, such as the metal composition of the component, the weight of the component, the date, time, and / or location when the component was manufactured, etc. The information encoded to the signal device 160 may also specify operating parameters and / or data about the component that are independent of the detectable physical characteristics of the component. The signal device 160 may be an RFID tag or card, a bar code label or tag, an integrated circuit (IC) board, or the like.

[0200] In some embodiments, the end surface 1102 of the proximal end 15 of the barrel frame 112 is substantially flat. In this configuration, if the barrel 104 is not coupled to the torch head 102, an operator can place a reader, such as an RFID reader mounted on a handheld device, against the substantially flat end surface 1102 to interrogate the signal device 160 and retrieve information stored on the signal device 160. Thus, the barrel frame 112 can be configured such that the signal device 160 mounted in or on the barrel frame 112 is read from within the plasma arc torch 10 (e.g., by the communication device 122 of the torch head 102) or from outside the plasma arc torch 10 (e.g., by an external reader).

[0201] In another aspect of the invention, the torch head 102 may be coupled to a cartridge that includes a discharge nozzle, in which case the torch head 102 still provides substantially the same functionality as if it were provided with a non-discharge cartridge 104 . Fig.261 is an exemplary discharge cartridge 1300 that is compatible with the torch head 102 of the plasma arc torch 10 of FIG. 1 according to an exemplary embodiment of the present invention. The cartridge frame 1302 of the discharge cartridge 1300 may be substantially identical in construction and / or material composition to the cartridge frame 112 of the non-discharge cartridge 104, such that the cartridge frame 1302 maintains the same interface between the components of the torch head 102 and the cartridge tip, including the electrode 1308, the discharge nozzle 1310 coupled to the nozzle bushing 1311, and the shroud 1314. For example, the electrode 1308 may be substantially identical to the electrode 108 of the non-discharge cartridge 104, and the electrode 1308 may be attached to the cartridge frame 1302 in the same manner as the electrode 108 is attached to the cartridge frame 112. The shroud 1314 may be substantially identical to the shroud 114 of the non-discharge cartridge 104, and the shroud 1314 may be attached to the cartridge frame 1302 in the same manner as the shroud 114 is attached to the cartridge frame 112.

[0202] The nozzle bushing 1311 may be disposed in and attached to the inner surface of the discharge nozzle 1310. Each of the nozzle bushing 1311 and the nozzle 1310 may be directly attached to the cartridge frame 1302 such that the nozzle bushing 1311 and the nozzle 1310 are aligned axially and radially with the cartridge frame 1302. In some embodiments, as shown in FIG. Fig.26 As shown in FIG. 1 , the radial distance 1360 between the inner surface of the swirl ring 1316 of the discharge barrel 1300 and the outer surface of the electrode 1308 is about 0.08 inches. In some embodiments, the closest breakdown gap distance 1362 between the outer surface of the electrode 108 and the inner surface of the nozzle bushing 1311 is about 0.05 inches.

[0203] 27a and 27b are respectively Fig.26 27b, the discharge nozzle 1310 includes a generally hollow body having a proximal end / portion 1326 and a distal end / portion 1328 along the longitudinal axis A of the welding torch 10. The distal end 1328 of the nozzle 1310 includes a centrally located nozzle outflow orifice 1332 for directing a plasma arc, such as an ionized gas jet, into a workpiece to be cut (not shown). In some embodiments, the nozzle 1310 includes a circumferential coolant channel 1339 (i.e., a flow channel extending approximately 360 degrees around the nozzle 110) around the outer surface of the nozzle 1310, which is located at the proximal end 1326. The circumferential channel 1339 allows liquid coolant to flow over the outer surface of the nozzle 1310 in a vortex flow pattern, thereby promoting convective cooling and reducing stagnation of the flowing liquid.

[0204] As shown in FIG. 27a, the nozzle bushing 1311 includes a generally hollow body defining a proximal end 1334 and a distal end 1336 along a longitudinal axis A. The nozzle bushing 1311 includes a central opening 1338 at the distal end 1336, and one or more plasma gas channels 1337 oriented longitudinally on the outer surface of the bushing 1311 around the central opening 1338. In some embodiments, the nozzle bushing 1311 includes one or more exhaust holes 1346 at its proximal end 1334 to allow the exhaust plasma gas flow to travel from the inner surface to the outer surface of the nozzle bushing 1311. The exhaust holes 1346 can be appropriately metered to control one or more flow parameters. The nozzle bushing 1311 is adapted to be disposed in the hollow body of the nozzle 1310 from an opening at the distal portion 1326 of the nozzle 1310. The nozzle bushing 1311 can be radially aligned / centered relative to the nozzle 1310. Once the nozzle bushing 1311 is disposed in the nozzle 1310, the central opening 1338 may be in fluid communication with the nozzle outlet orifice 1332. The distal end 1334 of the nozzle bushing 1311 may be exposed such that the discharge hole 1346 is not blocked by the nozzle 1310.

[0205] In some embodiments, the shield gas flow through the exhaust cartridge 1300 is substantially the same as the shield gas flow 868 through the non-exhaust cartridge 104. In some embodiments, the plasma gas flow through the cartridge frame 1302 is substantially the same as the plasma gas flow 900c through the cartridge frame 112. Fig.26 13 shows the plasma gas flow path after it flows out of the barrel frame 112. Substantially similar to the plasma gas flow path 900b of the barrel frame 112, the swirl ring 1316 can be configured to introduce a swirling motion into the plasma gas flow 1340 as it flows distally out of the barrel frame 1302. The plasma gas flow 1340 then travels distally between the electrode 1308 and the nozzle bushing 1311 to reach a chamber 1342 cooperatively defined by the electrode 1308, the nozzle bushing 1311, and the nozzle 1310. The plasma gas flow 1340 can flow out of the plasma arc torch 10 by traveling through the chamber 1342, the central opening 1338 of the nozzle bushing 1311, the central nozzle outflow orifice 1332, and the central shield outflow orifice 1344. A small portion 1341 of the plasma gas flow 1340 in the plenum 1342 may be exhausted distally through one or more plasma gas passages 1337 between an outer surface of the liner 1311 and an inner surface of the nozzle 1310 .

[0206] As the plasma gas stream 1341 travels distally between the bushing 1311 and the nozzle 1310, it reaches the proximal end 1324 of the nozzle bushing 1311 and may flow out of the nozzle bushing 1311 via the exhaust holes 1346 at the proximal end 1324, which connect the inner surface of the nozzle bushing body 1311 to the outer surface of the nozzle bushing body 1311. The exhaust holes 1346 are adapted to be in fluid communication with exhaust passages 1348, which are radially oriented in the body of the cartridge frame 1302 to connect the inner side surface of the cartridge frame 1302 and the outer side surface of the cartridge frame 1302 (which in turn is exposed to the atmosphere). In some embodiments, similar exhaust passages may be constructed in the insulating body 1100 of the cartridge frame 112 for a non-exhausted cartridge 112, so that the same through-frame may be used for both exhaust and non-exhausted cartridge designs. Thus, the distal plasma gas flow 1341 can flow out of the nozzle 1310 via the exhaust hole 1346 to enter the exhaust channel 1348 disposed in the body of the barrel frame 1302. The distal plasma gas flow 1341 can be exhausted to the atmosphere by following the exhaust channel 1348 from the inner surface to the outer surface of the barrel frame 1302. In some embodiments, if the retaining cap 120 is used to connect the barrel frame 1302 to the welding torch head 102, the exhaust hole disposed in the body of the retaining cap 120 can be aligned with the exhaust channel 1348 of the barrel frame to allow the distal plasma gas flow 1341 to escape from the welding torch 10. In essence, by allowing the plasma gas flow 1341 to be exhausted from the barrel 1300 instead of from the torch head 102, ozone in the plasma gas flow 1341 will not otherwise damage the welding torch 10 because the torch head 102 is a more durable component that can be reused, while the barrel 1300 is a consumable component that can be replaced regularly (e.g., approximately every 2 to 20 hours of operation, such as, approximately every 8 hours of operation) or after each use.

[0207] In some embodiments, the coolant flow through the barrel frame 1302 is substantially the same as the liquid coolant flow 950 through the barrel frame 112. In the discharge barrel 1300, the coolant flow can use the same coolant channels and passages / flow areas to cool the electrode 1308 and the shield 1314 in substantially the same manner as the coolant flow 950 of the non-discharge barrel 104. For example, cooling the electrode 1308 in the discharge barrel 1300 can be the same as cooling the electrode 108 of the non-discharge barrel 104 by using the main coolant channel 1002 connected to the cavity 954 of the electrode 108. As another example, cooling the shield 1314 in the discharge barrel 1300 can be the same as cooling the shield 114 of the non-discharge barrel 104 by using the third coolant channel 978 and the fourth coolant channel 982 connected to the shield coolant flow area 1222 of the shield 114.

[0208] With the discharge nozzle 1310 exiting the cartridge 1300 , the coolant flow through the cartridge frame 1302 is substantially the same as the liquid coolant flow 950 through the cartridge frame 112 over the first coolant passage 962 and the second coolant passage 968 . Fig.26 13 shows the coolant flow path toward the discharge nozzle 1310 after it flows out of the barrel frame 112. As shown, the opening 962b of the first coolant channel 962 located on the inner side surface of the barrel frame 1302 conducts the coolant flow 1350 from the inner area of ​​the barrel frame 1302 to the central main channel 1351 (e.g., the same as the main channel 1020 of the barrel frame 112). The coolant flow 1350 can travel distally on the main channel 1351 to exit the barrel 1302 and enter the nozzle coolant flow area 1352 defined between the circumferential channel 1339 on the outer surface of the nozzle 1310 and the inner surface of the shroud 1314. For example, the opening 962b of the first coolant channel 962 can be in fluid communication with the circumferential channel 1339 (and the nozzle coolant flow area 1352) so that it conducts the coolant flow 1350 from the barrel frame 1302 from one side of the nozzle 1310 to the nozzle coolant flow area 1352 in the center. The coolant flow 1350 may travel distally in the longitudinal direction toward the circumferential flow channel 1339 on one side of the nozzle coolant flow area 1352. Upon reaching the circumferential flow channel 1339, the coolant flow 1350 may swirl around the nozzle 1310 and return proximally on the other side of the nozzle 1310 that is substantially opposite (e.g., approximately 180 degrees) to the distal flow. The circumferential flow channel 1339 may also be in fluid communication with the opening 968b of the second coolant channel 968, so that the return flow 1350 may flow out of the nozzle coolant flow area 1352 and enter the barrel frame 1302 through the opening 968b of the second coolant channel 968.

[0209] In some embodiments, unlike coolant flow 950 relative to non-discharge nozzles 110, coolant flow 1350 for discharge barrel 1300 does not enter the area between liner 1311 and discharge nozzle 1310. Instead, coolant flow 1350 flows around the outer circumference of nozzle 1310 spaced distally relative to liner 1311.

[0210] In general, the barrel frame 112 for non-discharge barrel 104 and the barrel frame 1302 for discharge barrel 1300 may be the same. In certain embodiments, the same barrel frame can be used in different types of barrels by aligning and attaching different types of components to the barrel frame. For example, as described above, the barrel frame of the present invention can be connected to the nozzle of discharge or non-discharge, to customize the plasma gas discharge capacity. As another example, different swirl rings (e.g., swirl ring 150 or swirl ring 1316) can be attached to the barrel frame to customize the swirl flow pattern of the plasma gas flow through the barrel. As another example, different baffles (e.g., baffle 1112) or protective swirl rings (e.g., protective swirl ring 1114) can be attached to the barrel frame to customize the flow properties of the protective gas flow through the barrel. Therefore, the barrel frame of the present invention allows that the consumable barrel can be constructed and customized to achieve different cutting purposes.

[0211] Fig.28 Another exemplary cartridge frame 1400 according to an exemplary embodiment of the present invention is suitable for being configured to form a cartridge compatible with the torch head 102 of FIG. 1. The cartridge frame 1400 is substantially the same as the cartridge frame 112 or cartridge frame 1302. The main difference is the shape of the proximal end 1402 of the cartridge frame 1400 having a "petal" configuration. All other features of the cartridge frame 1400 including inlet and outlet openings and passages remain the same as those of the cartridge frame 112. The cartridge frame 1400 may be made of insulating material, such as Torlon™ or polyphenylene sulfide, as is the case with cartridge frame 112. The "petal" configuration of the proximal end 1402 of the cartridge frame 1400 allows the cartridge frame 1400 to be manufactured using injection molding technology, which provides a faster and cheaper manufacturing approach than conventional processes, including using less mass, better cooling, and more uniform without cavitation. In alternative embodiments, the cartridge frame 112 or 1400 may be machined.

[0212] In some embodiments, at least one of the nozzle jacket 111 or the electrode insulator 754 is made of a non-conductive material, such as Torlon™ or polyphenylene sulfide. At least one of the electrodes 108, 1308, the insert 1200, the non-discharge nozzle 110, the discharge nozzle 1310, the nozzle bushing 1311 or the shield 114, 1314 may be made of a conductive material such as copper or brass. The swirl ring 150, 1316 may be made of a conductive material such as zinc (e.g., Zamac3). Each of the baffle 1112 or the protective swirl ring 1114 may be made of an insulating material or a conductive material. In some embodiments, each of the non-discharge cylinder 104 or the discharge cylinder 1300 is made of at least about 50% plastic by volume. In some embodiments, the overall length of the cylinder 104 or 1300 along the longitudinal axis A is about 2 inches, and the maximum diameter of the cylinder 104 or 1300 along the plane perpendicular to the longitudinal axis A is about 1.7 inches.

[0213] The electrodes 108, 1308 and shields 114, 1314 can be manufactured using cold forming, stamping or machining techniques. The non-discharge nozzle 110 or the discharge nozzle 1310 can be manufactured using cold forming, stamping or machining, and have features (e.g., holes) drilled therein. The swirl rings 150, 1316 can be manufactured using die casting with drilled swirl holes therein, injection molding with drilled swirl holes therein, or machining. The baffle 1112 can be formed using stamping, die casting, machining or molding. The protective swirl ring 1114 can be formed using die casting, molding or machining. In general, to reduce manufacturing costs and complexity, the barrel 104 or 1300 includes little or no Vespel TM , little or no lava, little or no aluminum, minimal copper usage, and / or few O-ring grooves. In addition, the components of the cartridge 104, 1300 are manufactured to minimize holes that need to be drilled.

[0214] In some embodiments, the barrel 104 or barrel 1300 is designed to be non-planar in the proximal end so that the interface between the barrel and the torch head 102 is also non-planar. Fig.29 1450 is an exemplary discharge barrel 1450 including a non-flat proximal end 1452 according to an exemplary embodiment of the present invention. The discharge barrel 1450 may include an end face 1458 and a protruding distal portion 1460 disposed on a barrel frame 1454. Specifically, the protruding distal portion 1460 is a part of the barrel frame 1454 that forms the main central channel 1456. The protruding distal portion 1460 may extend distally beyond the end face 1458 of the inner region 1462 of the barrel frame 1454 along the longitudinal axis A. All other features / functions of the barrel 1450 may remain substantially the same as the discharge barrel 1300 described above.

[0215] Fig.30 According to an exemplary embodiment of the present invention Fig.181202. To assemble the cartridge 104, the radioactive insert 1200 may first be inserted into the electrode 108 at the distal end 1202 of the electrode 108. The electrode 108 may then be coupled to the electrode insulator 754 from the distal end of the electrode insulator 754. For example, the outer retaining features 1066 of the electrode 108 may matingly engage the inner retaining features 1068 of the electrode 754 to axially align the components and / or to align / center them radially along the interface 1067. The resulting component may be coupled to the swirl ring 150 to form a first subassembly 1502. For example, the outer retaining features 1056 of the electrode insulator 754 may matingly engage the inner retaining features 1054 of the swirl ring 150 to axially align the components and to align / center them radially along the interface 1055. In some embodiments, one or more O-rings are used to further secure the components (e.g., swirl ring 150, electrical insulator 75, and electrode 108) relative to each other in first subassembly 1502. Second subassembly 1504 may be formed by attaching nozzle 110 to nozzle jacket 111, wherein nozzle 110 may be disposed within a hollow body of nozzle jacket 111. In some embodiments, one or more O-rings are used to further secure nozzle 110 and nozzle jacket 111 relative to each other in second subassembly 1504.

[0216] The first subassembly 1502, the second subassembly 1504 and the shroud 114 can be directly attached to the barrel frame 112 to form the barrel 104. For example, the outer retaining feature 1052 of the swirl ring 150 can be matingly engaged with the inner retaining feature 1058 of the barrel frame 112 to align the components axially and align / center them radially along the interface 1053. The outer retaining feature 1070 of the nozzle 110 can be matingly engaged with another inner retaining feature 1072 of the barrel frame 112 to align the components axially and / or align / center them radially along the interface 1071. The outer retaining feature 1062 of the barrel frame 112 can be matingly engaged with the inner retaining feature 1064 of the shroud 114 to align the components axially and align / center them radially along the interface 1063. In addition, the distal end of the shroud 114 can be crimped into a recess 1065 on the outer surface of the barrel frame 112 to further secure the two components together. In some embodiments, one or more O-rings are used to assist in coupling the first subassembly 1502 , the second subassembly 1504 , and / or the shroud 114 to the cartridge frame 112 .

[0217] It should be understood that the various aspects and embodiments of the present invention can be combined in various ways. Based on the teachings of this specification, a person skilled in the art can easily determine how to combine these various embodiments. A person skilled in the art will think of modifications when consulting the specification.

Claims

1. A consumable cartridge for a liquid-cooled plasma arc torch, the consumable cartridge comprising: a non-conductive cartridge frame having a proximal region and a distal region, the proximal region being removably connectable to the torch head; a set of conductive consumable members partially defining a plasma chamber, wherein the set of conductive consumable members includes at least a first consumable member and a second consumable member, the set of conductive consumable members being attached to the distal region of the cartridge frame, a first liquid passage disposed in and defined by the cartridge frame, the first liquid passage configured to conduct a first fluid flow received from the torch head from the proximal region of the cartridge frame to the distal region to contact the first consumable component; and a first gas passage disposed in and defined by the cartridge frame, the first gas passage being configured to conduct a second fluid flow received from the torch head from a proximal region of an insulating body of the cartridge frame to a distal region of the insulating body to contact the second consumable member, wherein the consumable cartridge is composed of at least 50% non-conductive material by volume, and the first liquid channel and the first gas channel are non-concentric and offset relative to a central longitudinal axis, and wherein the proximal region of the cartridge frame has a synchronization feature configured to secure the torch head to the cartridge frame in a predetermined radial orientation to allow alignment of electrical, liquid, and gas passages between the torch head and the cartridge frame.

2. The consumable material cartridge according to claim 1, wherein: The consumable tube is composed of 60% to 80% non-conductive material by volume.

3. The consumable material cartridge according to claim 1, wherein: The consumable cartridge is a single-use cartridge.

4. The consumable material cartridge according to claim 1, wherein: The set of conductive consumable members are not individually disposable after being attached to the cartridge frame.

5. The consumable material cartridge according to claim 1, wherein: The set of conductive consumable components includes a shield, a nozzle, and an electrode.

6. The consumable material cartridge according to claim 1, wherein: The cartridge frame includes a plurality of liquid channels in fluid communication with the set of conductive consumable members, the liquid channels being non-concentric and offset relative to the central longitudinal axis of the cartridge frame.

7. The consumable material cartridge according to claim 6, wherein: The plurality of liquid channels include: a first liquid passage; and A return passage is disposed in the insulative body and is configured to conduct at least a portion of the first fluid flow from the first consumable component to the torch head.

8. The consumable material cartridge according to claim 1, wherein: The first consumable component is a nozzle or a shield.

9. The consumable cartridge of claim 1, further comprising a cavity disposed in the cartridge frame adjacent the proximal region, the cavity being configured to receive a radio frequency identification (RFID) tag for communicating with a reader of the torch head.

10. The consumable material cartridge according to claim 1, wherein: The barrel frame includes a central channel extending along and concentric with the central longitudinal axis of the barrel frame, and the central channel is configured to perform at least one of the following: (i) conduct a third fluid flow from the welding torch head to the electrode in the group of conductive consumable components, or (ii) transfer electric current from the welding torch head to the electrode.

11. The consumable material cartridge according to claim 1, wherein: The second fluid flow includes a shield gas flow and the second consumable component in contact with the first gas channel includes a shield.

Images