Consumable for a plasma arc torch

Abstract

A consumable for a cutting torch includes a distributor, an electrode, and a nozzle. The distributor defines a plurality of ports extending from an interior cavity of the distributor to an exterior surface of the distributor. The electrode is disposed within the distributor and is non-removably, fixedly coupled to the distributor. The nozzle defines at least one set of passages that direct a gas into a gap defined between the electrode and the nozzle, the nozzle being non-removably, fixedly coupled to the distributor.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application Serial No. 17 / 167,338, filed February 4, 2021, entitled “Consumables for Processing Torches,” the disclosure of which is incorporated herein by reference in its entirety for all purposes. Technical Field

[0003] This disclosure relates to components for welding torches and cutting torches, and more particularly to consumable components for welding torches and / or cutting torches. Background Technology

[0004] Many welding and cutting torches (such as plasma cutting torches) can accommodate a variety of consumable parts, such as tips / nozzles, electrodes, and shields. Typically, consumables (such as electrodes, tips / nozzles, and shields) have a limited lifespan and only last for a certain amount of cutting or welding before the user must replace them. Therefore, consumables with longer lifespans can save users time, as they can continue cutting or welding operations without replacing them. Furthermore, consumables with longer lifespans can provide cost savings for users, as they will not need to frequently purchase replacements. Therefore, consumables with improved lifespans are consistently desirable.

[0005] Various factors influence the lifespan of consumables. For example, consumables exposed to molten slag and direct heat from the electric arc may wear out faster than those protected or indirectly exposed (e.g., disposed within another component) from the effects of molten slag and heat. As another example, small defects can render a consumable unusable (i.e., end its lifespan) if it moves (e.g., slides or translates) and / or is fragile before, during, or after a processing operation. For instance, small defects can create unacceptable movement patterns and / or unacceptable tolerances between parts, preventing the consumable from performing its intended function. Therefore, in at least some cases, movable consumables can have a reduced lifespan compared to stationary consumables. This can be particularly true for electrodes that are frequently struck by an electric arc and must then support the arc from a precise location (e.g., from a small firing insert included at its distal end). As yet another example, the amount of cooling acting on a consumable can significantly affect its lifespan.

[0006] Furthermore, in many conventional welding and / or cutting torches, consumable sets consist of multiple individual consumable parts, which often need to be disassembled or reassembled to replace one or more parts. This requires end users to stock a wide variety of parts and can make even the replacement of a single consumable a timely and / or difficult task. For example, if an electrode is worn and damaged, it can be difficult to remove the electrode from the remaining consumables, replace the electrode, and reassemble the consumable set. Additionally, in at least some cases, it can be difficult to identify which consumable in a set needs replacement. Therefore, consumable sets that can be easily installed onto the torch head are consistently desirable. Summary of the Invention

[0007] This disclosure relates to consumables for cutting torches. Consumables may be provided individually in a single-piece box and / or in sub-boxes, the single-piece box being non-repairable and formed of components that are non-removably connected to each other, the sub-boxes being each single-piece / non-repairable but connectable to other components or sub-boxes to form a complete consumable box.

[0008] In at least some embodiments, the consumables in the integrated box and / or sub-box presented herein are fixed or stationary, and are therefore precisely aligned and arranged relative to other consumables in the integrated box and / or sub-box, which can extend the lifespan of individual consumables. Alternatively, one or more components of the integrated box and / or sub-box presented herein may include movable parts, such as movable arc initiators, but may include fixed tips and fixed electrodes, which can extend the lifespan of these critical consumable components, which are typically the consumable components with the shortest lifespan. Furthermore, in yet another embodiment, the electrodes or tips of the integrated box and / or sub-box presented herein may be movable during arc initiation, but may otherwise be fixed within the box so that the end user does not need to repair or assemble the box or sub-box.

[0009] According to one example embodiment, a consumable assembly for a plasma arc torch includes a dispenser, a nozzle, and a locking ring. The dispenser defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser. The nozzle includes a first set of channels and a second set of channels. The first set of channels extends from the internal cavity of the nozzle to the external surface of the nozzle. The second set of channels extends from the external surface of the nozzle to an undercut portion of the nozzle. The locking ring is configured to secure the dispenser to the nozzle in a non-removable manner. Thus, using only three components, this consumable assembly can form both a protective gas passage and a plasma gas passage within consumables that are non-removably fixed together and non-repairable. Because the consumables are non-removably fixed together, each passage can be precisely profiled and oriented.

[0010] In at least some of the embodiments, the consumable set also includes an electrode non-removably connected to the dispenser. Additionally or alternatively, the consumable set may include a static arc initiator located within the dispenser and positioned to extend into the gap between the nozzle and the electrode disposed within the nozzle. Embodiments with a static arc initiator can form a completely static cartridge or sub-cartridge, and thus can extend the lifespan of the consumables.

[0011] In some embodiments, the nozzle includes a proximal portion and a distal portion, and a first set of channels and a second set of channels extend through the proximal portion. In some of these embodiments, the distal portion defines an orifice providing an outlet from an internal cavity of the nozzle, the first set of channels defines a gas passage to the orifice, and the second set of channels defines a gas passage allowing gas to flow across the outer surface of the distal portion and around the orifice. Additionally or alternatively, an undercut portion extends longitudinally into the bottom surface of the proximal portion of the nozzle.

[0012] In some embodiments, the dispenser defines an upper shoulder, the nozzle defines a lower shoulder, and the locking ring further includes an upstream end and a downstream end. The upstream end is configured to engage the upper shoulder, and the downstream end is configured to engage the lower shoulder. Thus, the locking ring can mechanically secure the dispenser and the nozzle while providing a fluid passage between the exteriors of these components and providing electrical connection to these components when needed. In some embodiments of these embodiments, the upstream end defines a first opening having a first diameter, and the downstream end defines a second opening having a second diameter, the first diameter being smaller than the second diameter. Additionally or alternatively, the lower shoulder of the nozzle defines a boundary of an undercut portion, and the downstream end of the locking ring is configured to extend beyond the lower shoulder to the boundary.

[0013] Furthermore, in some embodiments, the proximal end of the nozzle defines a seat, and a locking ring is configured to compress the dispenser into the seat. Additionally or alternatively, the consumable assembly may also include a shield cup configured to mechanically connect the consumable assembly to the operating end of the torch and electrically connect the nozzle to an electrical conductor in the torch.

[0014] According to another example embodiment, a consumable assembly for a plasma arc torch includes a dispenser, electrodes, and nozzles. The dispenser defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser. The electrodes are disposed within the dispenser and are non-removably and fixedly coupled to the dispenser. The nozzles define at least one set of channels that guide gas into a gap defined between the electrodes and nozzles and are non-removably and fixedly coupled to the dispenser. Because the electrodes and nozzles are each non-removably and fixedly coupled to the dispenser, these consumables can be precisely positioned and aligned relative to each other, which maximizes the lifespan of these components.

[0015] In at least some of these embodiments, the consumable assembly further includes a locking ring extending around a proximal end of the dispenser and a distal end of the nozzle to non-removably and securely couple the dispenser to the nozzle. For example, the dispenser may define an upper shoulder, the nozzle may define a lower shoulder, and the locking ring may include an upstream end configured to engage the upper shoulder and the downstream end configured to engage the lower shoulder.

[0016] As described above, in at least some embodiments, the electrodes are stationary. Additionally or alternatively, the consumable assembly may include a stationary arc initiator located in the dispenser and positioned to extend into the gap between the electrode and the nozzle. Embodiments with a stationary arc initiator can form a completely stationary cartridge or sub-cartridge, and thus can extend the life of the consumables.

[0017] Furthermore, in some embodiments, the consumable assembly may include a shield cup configured to mechanically connect the consumable assembly to the operating end of the torch and electrically connect the nozzle to an electrical conductor in the torch. Additionally, some embodiments with a shield cup may also include a shroud. The shroud and shield cup may together surround the nozzle to protect it from splashing.

[0018] According to yet another example, a consumable assembly for a plasma arc torch includes a first sub-box and a second sub-box. The first sub-box includes a dispenser, an electrode, and a nozzle. The dispenser defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser. The electrode is disposed within the dispenser and is non-removably and fixedly coupled to the dispenser. The nozzle defines at least one set of channels that guide gas into a gap defined between the electrode and the nozzle and is non-removably and fixedly coupled to the dispenser. The second sub-box includes a shroud and a shroud cup. The shroud is configured to cover the distal end of the nozzle. The shroud cup is non-removably and fixedly coupled to the shroud. The shroud and the shroud cup define a seat configured to receive the first sub-box, and the shroud cup includes a connector capable of connecting the second sub-box, together with the first sub-box located within the second sub-box, to an operating end of the torch. Thus, the first and second sub-boxes can form a single, non-repairable box that can be connected to or removed from the torch with a single action.

[0019] In some embodiments, the shield cup includes a first connector and a second connector. The first connector electrically connects the shield to one or more electrical conductors in the torch. The second connector electrically connects the nozzle to one or more conductors in the torch. Thus, when the shield cup is mechanically connected to the torch (e.g., in a single action), the cup can be electrically connected to the torch in a manner that allows for arc initiation.

[0020] Other systems, methods, features, and advantages will be apparent to or will become apparent to those skilled in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are included in this specification and within the scope of the claimed subject matter. Attached Figure Description

[0021] The consumables of the plasma arc torch presented herein can be better understood by referring to the following figures and descriptions. It should be understood that the components in the figures are not necessarily drawn to scale, and the emphasis has been placed on the principles underlying the illustrated consumables. In the figures, the same reference numerals denote corresponding parts throughout different views.

[0022] Figure 1A This is a perspective view of a manual cutting system according to an exemplary embodiment of the present disclosure, the manual cutting system including a power source and a torch assembly that can utilize the consumables presented herein.

[0023] Figure 1B This is a three-dimensional view of the torch assembly in Figure 1.

[0024] Figure 1C This is a perspective view of an automatic cutting head for consumables that can be used according to an exemplary embodiment of the present disclosure.

[0025] Figure 2A This is a side perspective view of a consumable box formed by an example embodiment of the consumable presented herein.

[0026] Figure 2B yes Figure 2A A side sectional view of the consumables box.

[0027] Figure 3 It is possible to form according to the example embodiment. Figure 2A A three-dimensional side view of two consumable boxes or consumable sub-boxes of a consumable box.

[0028] Figure 4 According to the example embodiment Figure 3 An exploded view of the first consumable sub-box.

[0029] Figure 5 It is according to the example embodiment that can be used to form Figure 4 A side sectional view of a sub-box of a consumables sub-box.

[0030] Figures 6A-6C The example embodiments are depicted including Figure 4 Top perspective view, bottom perspective view and side sectional view of the dispenser in the first consumable sub-box.

[0031] Figures 7A-7C The example embodiments are depicted including Figure 4Side perspective view, bottom perspective view and side sectional view of the nozzle in the first consumable sub-box.

[0032] Figures 8A-8C The example embodiments are depicted including Figure 4 Top perspective view, bottom perspective view and side sectional view of the locking ring in the first consumable sub-box.

[0033] Figures 9A-9C The example embodiments are depicted including Figure 4 Top perspective view, bottom perspective view and side sectional view of the electrodes in the first consumable sub-box.

[0034] Figure 10 According to the example embodiment Figure 3 An exploded view of the second consumable sub-box.

[0035] Figure 11 yes Figure 10 A side sectional view of the second consumable sub-box.

[0036] Figures 12A-12C The example embodiments are depicted including Figure 10 Top perspective view, side perspective view and bottom view of the protective cover in the second consumable box.

[0037] Figure 13A and Figure 13B The example embodiments are depicted including Figure 10 Top perspective view and side sectional view of the shield cup in the second consumable box.

[0038] Figure 13C and Figure 13D The example embodiments are depicted including Figure 13A and Figure 13B A side perspective view of the conductive connector in the protective cup.

[0039] Figure 13E It is included according to the example embodiments Figure 13A and Figure 13B A three-dimensional view of the side of the insulating sleeve in the protective cup.

[0040] Figures 14-20 This is a schematic diagram depicting an example launch method used with the consumables and / or boxes presented herein. Detailed Implementation

[0041] This document presents consumables for cutting torches and / or welding torches. Consumables may be supplied individually or packaged in one or more consumable cases. When packaged in a consumable case, the consumables may be non-removably coupled together, making the included consumables non-repairable. That is, the non-removable coupling can create a non-removable, one-piece case. Therefore, the one-piece consumable case can be attached to or removed from the torch in a single action. Alternatively, the consumables presented herein may be non-removably coupled to other components to form sub-cases, which may be removably or non-removably coupled to additional consumables or sub-cases to form a case. The resulting case can still be coupled to the torch in a single action.

[0042] Regardless of whether the consumables presented herein are part of an integrated housing, in at least some embodiments, the consumables do not move relative to each other before, during, or after processing operations (including during arc initiation). That is, the consumables can be stationary. This ensures that the consumables are properly aligned, secured, and oriented relative to each other, which in turn maximizes the lifespan of the consumables. By comparison, a consumable that moves precisely relative to other consumables may fail (i.e., reach the end of its lifespan) when wear prevents the consistent execution of precise movement and / or reduces the function of a particular component (e.g., if wear reduces the function of a spring). The consumables presented herein are also more robust and less prone to manufacturing defects compared to consumables configured to perform precise movement and / or include components configured to perform precise movement.

[0043] Figure 1A An example embodiment of a manual cutting system 10 using the consumable components presented herein is illustrated. At a high level, the manual cutting system 10 includes a power source 12 and a torch assembly 40. The power source 12 is configured to supply (or at least control) electricity and gas to a torch 50 included in the torch assembly 40 via a torch lead 42 (also referred to as a cable hose 42). For example, the power source 12 may meter the gas flow rate received from a gas source 20 before or during the supply of gas to the torch 50 via the cable hose 42.

[0044] The manual cutting system 10 also includes a working lead assembly 30 with a grounding clamp 32 connected to a power source via a working lead 34 (also referred to as cable hose 34). As illustrated, cable hoses 22, 34, and 42 can all be of any length. Furthermore, each end of cable hoses 22, 34, and 42 can be connected to a component of the manual cutting system 10 via any connector now known or developed below (e.g., via a releasable connector). For example, torch 50 can be connected to the distal end of cable hose 42 via quick-disconnect connector 46, and power source 12 can be connected to the proximal end of cable hose 42 via quick-disconnect connector 44.

[0045] Figure 1B The diagram illustrates a power supply independent of power supply 12. Figure 1A The torch assembly 40. As can be seen, the torch 50 includes a torch body 52 extending from a first end 56 (e.g., a connection end 56) to a second end 54 (e.g., a manipulation end or operating end 54). The torch body 52 may also include a trigger 58 that allows a user to initiate a cutting operation in any manner now known or later developed (e.g., in 2T or 4T mode). As described above, the connection end 56 of the torch body 52 can be coupled (in any manner now known or later developed) to one end of the lead wire 42. Meanwhile, the operating end 54 of the torch body 52 can receive interchangeable components, such as consumable components that facilitate the cutting operation. The consumable stack presented herein (in Figure 1B (Depicted as being installed on torch 50) Figure 1B This is commonly referred to as Consumables Pile 70; however, in Figure 1B The depiction shown represents only the consumable pile including the features presented herein.

[0046] Figure 1C An example embodiment of an automated cutting head 60 utilizing the consumable components presented herein is illustrated. As can be seen, the cutting head 60 includes a body 62 extending from a first end 63 (e.g., a connection end 63) to a second end 64 (e.g., a manipulating end or operating end 64). The connection end 63 of the body 62 can be coupled (in any manner now known or later developed) to an automated support structure (e.g., a cutting table, robot, gantry, etc.), and a conduit 65 extending from the connection end can be coupled to similar conduits in the automated support structure to connect the automated cutting head 60 to a power source, gas source, coolant source, and / or any other component supporting automated cutting operations. Meanwhile, the operating end 64 of the body 62 can receive interchangeable components, including consumable components that facilitate cutting operations. Furthermore, Figure 1C The consumable pile 70 described herein refers only to consumable piles that include the features presented herein (such as...). Figure 1B The pile depicted in the text (70).

[0047] For simplicity, Figure 1A , Figure 1B and Figure 1C The interior of torch body 52 or body 62 is not shown. However, it should be understood that any unshown components typically included in the torch (such as components facilitating welding or cutting operations) can (and should) be included in the torch configured according to an exemplary embodiment of the invention. Additionally, Figure 1A , Figure 1B and Figure 1C The connection portions of body 52 / 62 are not shown in detail in the other accompanying drawings; however, it should be understood that the consumables presented herein can be coupled to torch body 52 / 62, which includes features configured to match the characteristics of the consumables, examples of which are described in detail below.

[0048] Consumable Box

[0049] Turn now Figure 2A and Figure 2B These figures provide perspective and cross-sectional views of a first example embodiment of a consumable cartridge 80 formed by the consumables presented herein. The consumable cartridge 80 includes a dispenser 120, an arc initiator 140, a nozzle 150, a locking ring 180, an electrode 190, a shroud 210, and a shroud cup 240. However, this example is not intended to suggest that the consumable cartridge 80 cannot include additional components combined with the dispenser 120, arc initiator 140, nozzle 150 (also referred to as tip 150), locking ring 180, electrode 190, shroud 210, and shroud cup 240. For example, the consumable cartridge 80 may also include gas management components, mechanical components, magnetic components, and / or any other components that aid in initiating an arc. The following at least incorporates... Figures 14 to 20 Some example additional components are described in further detail. Furthermore, one or more of the dispenser 120, arc initiator 140, nozzle 150, locking ring 180, electrode 190, shield 210, and shield cup 240 may be modified in different embodiments of the consumable box 80.

[0050] In at least some embodiments, the consumable components of the consumable box 80 are interconnected in a non-removable manner, making the consumable box 80 a single, non-repairable unit. In these cases, the consumable box 80 can be installed onto (or removed from) the torch body (e.g., body 52 or body 62) in a single action and can be disposed of when one or more of the included consumables need to be replaced (e.g., at the end of the life of a consumable). However, in other embodiments, the consumable box 80 may be formed from one or more “sub-boxes” (i.e., boxes that can be combined with other consumables and / or boxes) and / or one or more individual consumables. That is, the consumable box 80 may be formed from any other combination of two sub-boxes, two sub-boxes, and a single (i.e., loose) consumable or component.

[0051] Additionally, in some cases, each of the consumables included in the consumable cartridge 80 can be fixed in place once they are interconnected. That is, once the consumable cartridge 80 is fully assembled, each of the aforementioned consumables can be fixed relative to the other consumables included in the consumable cartridge 80, and the consumable cartridge 80 can include stationary consumables. Alternatively, some embodiments may include movable components for initiating an electric arc, but the electrode 190 and / or nozzle 150 may be fixed and stationary, which may be important because the tip 150 and electrode 190 are key components involved in arc initiation and plasma generation (especially electrode 190), and may suffer considerable wear and / or poor cutting performance / characteristics if not properly aligned and / or positioned. That is, in other embodiments, one or more consumable components of the consumable cartridge 80 (including electrode 190 and / or nozzle 150) may be movable within the consumable cartridge 80.

[0052] In the depicted embodiment, the consumable cartridge 80 extends from a proximal end 82 to a distal end 84. The proximal end 82 defines a fluid inlet passage 86, and the distal end 84 defines one or more openings that allow fluid to exit the consumable cartridge 80. The fluid inlet passage 86 is primarily defined by the dispenser 120 and is designed to receive fluid "F" (e.g., gas) from a corresponding conduit in the torch body (e.g., torch body 52 or 62). Meanwhile, in the depicted embodiment, the shroud 210 defines a central orifice 214 surrounded by a set of holes 230 that allow fluid to exit the consumable cartridge 80.

[0053] More specifically, in the depicted embodiment, electrode 190 is located within dispenser 120 to force fluid F entering fluid inlet channel 86 to flow radially outward within consumable cartridge 80. Locking ring 180 then works with nozzle 150 and dispenser 120 to define an annular external axial channel 87 that guides fluid F toward a first fluid path 88 and a second fluid path 90. First fluid path 88 creates a flow of protective fluid (e.g., protective gas) between nozzle 150 and shroud 210 and shroud cup 240. Second fluid path 90 guides fluid F toward plasma chamber 92 into the gap between nozzle 150 and electrode 190 to supply fluid toward the arc, thereby limiting the arc and generating a plasma flow (via ionization of fluid F) that can exit orifice 214 (after exiting the orifice of nozzle 150). The fluid F guided along the first fluid path 88 can exit the consumable box 80 via the orifice 230 and / or the port 214 to limit and protect the transmitted electric arc and / or plasma.

[0054] The proximal end 82 of the consumable cartridge 80 also includes a connector that mechanically and electrically connects the consumable cartridge 80 to a corresponding connector included in the torch body (e.g., torch body 52 or 62). Specifically, in the depicted embodiment, the first connector 242 of the electrode 190 and the shield cup 240, and the second connector 252 of the shield cup 240 protrude from the proximal end 82 of the consumable cartridge 80. The first connector 242 and the second connector 252 can mechanically couple the consumable cartridge 80 to the torch body (e.g., torch body 52 or 62). For example, the first connector 242 and the second connector 252 can be locked to corresponding features of the torch body (e.g., torch body 52 or 62) via a partially rotationally locking arrangement. However, the first connector 242 and the second connector 252 are merely examples, and in other embodiments, the consumable cartridge 80 can be coupled to the torch body in any manner known now or developed hereafter (including via threads, pawl arrangements, snap-fit ​​engagements, friction engagements, etc.).

[0055] Additionally, connectors 242, 252, and electrode 190 can electrically connect the consumable cartridge 80 to the torch body (e.g., torch body 52 or 62). First connector 242 connects nozzle 150 to an anode element included in the torch body (e.g., torch body 52 or 62) and / or grounds it, while second connector 252 can independently ground the shroud 210. Simultaneously, electrode 190 can be connected to a cathode element included in the torch body (e.g., torch body 52 or 62) to provide a negative potential to electrode 190. Precise electrical connection may depend on whether an arc can be maintained between nozzle 150 and electrode 190 before the arc is transmitted to the workpiece (or, for example, if the cartridge is initiated using a scraping mechanism).

[0056] Turn now Figure 3 As mentioned, in some cases, the consumable boxes formed by the consumables presented herein are formed by one or more sub-boxes on their own or in combination with one or more sub-boxes of individual consumables. Figure 3 An example embodiment of a consumable box 80' formed by two sub-boxes is illustrated: sub-box 100 and sub-box 200 (also referred to herein as "boxes" 100 and 200). Sub-box 100 includes a dispenser 120, an arc initiator 140, a nozzle 150, a locking ring 180, and an electrode 190. Sub-box 200 includes a shield 210 and a shield cup 240.

[0057] In the depicted embodiments, sub-cassette 100 is removably coupled to sub-cassette 200. For example, the distal end 104 of sub-cassette 100 can be inserted into the proximal end 202 of sub-cassette 200 (towards the distal end 204), and the internal geometry of sub-cassette 200 naturally allows sub-cassette 100 to be located and aligned within sub-cassette 200. In some embodiments, sub-cassette 200 may also include features such as pawls, friction fittings, threads, etc., that removably or non-removably secure sub-cassette 100 therein. In either case, consumable cassette 80' can be mounted to torch body (e.g., torch body 52 or 62) by having sub-cassette 100 located within sub-cassette 200 and then mounting cassette 80' to torch body (e.g., torch body 52 or 62). Alternatively, the proximal end 102 of sub-cassette 100 can be attached to torch body and then sub-cassette 200 can be mounted over and around sub-cassette 100 to form cassette 80' on torch.

[0058] Regardless of how the consumable box 80' is assembled together, the components of sub-boxes 100 and 200 are characterized, connected, and flow paths that are similar (if not identical) to those of the consumable box 80. Therefore, any description of the characteristics, connections, and flow paths of the consumable box 80 included herein, except that the consumable box 80 is described as an integral box with non-removable components, can be applied to the consumable box 80'.

[0059] First Consumable Box

[0060] Turn now Figures 4 to 9C These figures depict one or more components included in sub-casing 100. As described above, in the depicted embodiments, sub-casing 100 includes a dispenser 120, an arc initiator 140, a tip / nozzle 150, a locking ring 180, and an electrode 190. In some embodiments, each of these components may be manufactured independently and non-removably coupled together to form sub-casing 100. Alternatively, one or more of these components may be individually packaged and removably coupled to other components of sub-casing 100. To illustrate this, Figure 4An exploded view of the components included in sub-box 100 is provided. Figure 5 A view of sub-box 101, which can be used to form sub-box 100, is provided, and Figures 6A to 9C Individual components that can be used to form box 80, sub-box 100, and / or sub-box 101 are depicted. It is worth noting that... Figure 5 In this configuration, sub-box 101 includes a distributor 120, an arc initiator 140, a tip 150, and a locking ring 180, while electrode 190 is independently disposed and removably or non-removably coupled to sub-box 101 (e.g., via an end user).

[0061] like Figure 4 and Figure 5 As shown, for assembling sub-box 100 or sub-box 101, dispenser 120 is located in dispenser seat 1542 defined by tip 150. Locking ring 180 is then secured around dispenser 120 and tip 150, non-removably securing dispenser 120 to tip 150. For example, locking ring 180 can be forged onto dispenser 120 and tip 150. Alternatively, locking ring 180 can comprise two parts that are joined together once mounted on dispenser 120 and tip 150, such as via welding, to non-removably couple dispenser 120 to tip 150. As yet another example, locking ring 180 can be formed around dispenser 120 and tip 150 using additive manufacturing processes (e.g., 3D printing).

[0062] Regardless of how the locking ring 180 is formed / installed, the locking ring 180 can be secured against the radial flange 128 included on the dispenser 120 and the radial flange 164 included on the tip 150. More specifically, the upstream end 182 of the locking ring 180 can engage the upper seat surface 126 defined by the radial flange 128 of the dispenser 120, and the downstream end 186 of the locking ring 180 can engage the lower seat surface 165 defined by the radial flange 164 of the tip 150. This clamps the dispenser 120 against the tip 150 (or vice versa) and ensures that the dispenser 120 is securely and permanently positioned in the dispenser seat 1542 defined by the tip 150 (see See...). Figure 7C ).

[0063] The radial flange 128 of the dispenser 120 is disposed above the bore 130 of the dispenser 120 (e.g., proximal along the longitudinal direction). Simultaneously, the radial flange 164 may be below both bores 160 and 162 included in the tip 150 (e.g., proximal along the longitudinal direction). Thus, securing the dispenser 120 non-removably to the tip 150 using the locking ring 180 forms a sub-casing 101 defining multiple fluid passages; however, the fluid passages may not be fully defined until the electrode 190 is also mounted therein.

[0064] More specifically, the distributor 120 typically defines a fluid inlet passage 106, through which fluid F can enter the internal cavity 132 of the distributor 120. The fluid F can exit the internal cavity 132 via the orifice 130 and move to contact the inner surface 1842 of the sidewall 184 of the locking ring 180, which guides the fluid F distally toward the orifices 160 and 162 of the tip 150. That is, because the locking ring 180 is secured against the radial flange 128 of the distributor 120 and the radial flange 164 of the tip 150, the locking ring 180 can form an axial (and annular) channel between the exterior of the orifice 130 and the exterior of the orifices 160, 162.

[0065] Fluid dynamics principles (e.g., fluid along the path of least resistance) naturally separate the fluid F between orifice 160 and orifice 162. Therefore, some fluid F can enter orifice 160 along the first fluid path 114 to enter the internal cavity 152 of tip 150 (which can be separated from the internal cavity 132 of dispenser 120 by an electrode 190 mounted therein) and flow toward orifice 172 of tip 150. Conversely, some fluid F can enter orifice 162, pass through radial flange 164, and move to contact the outer surface 176 of the distal region of distal portion 170, for example, to radially form a protective airflow outside orifice 172.

[0066] See also Figure 4 and Figure 5 In the depicted embodiments, sub-box 100 and / or sub-box 101 include an arc initiator 140, which is fixedly and non-removably secured in the distributor 120. As described in further detail below, the arc initiator 140 allows the sub-box 100 to strike an arc (e.g., an arc that can be blown out of the sub-box 100 to transfer an arc to a workpiece). The arc initiator 140 extends from a first end 142 to a second end 144 and may include a step 146 disposed therebetween. The overall shape and size of the arc initiator 140 (including the dimensions and location of the step 146) allow the arc initiator 140 to be secured within an axial bore 134 formed in the distributor 120. For example, the arc initiator 140 may be press-fitted into the arc initiation bore 134 to secure the arc initiator 140 non-removably therein. Alternatively, the distributor 120 may be formed around the arc initiator 140, such as via overmolding or other similar manufacturing techniques. However, the arc initiator 140 is not required to be included in sub-box 100 or sub-box 101, and is only provided as an example component capable of initiating an arc for sub-box 100 or sub-box 101.

[0067] Consumable parts

[0068] Turn now Figures 6A to 6CIn the depicted embodiment, dispenser 120 is an annular component extending from a proximal or upstream end 122 to a distal or downstream end 124 surrounding an internal cavity 132. An upstream or proximal segment 1222 extends from the proximal end 122, a downstream or distal segment 1242 extends from the distal end 124, and a radial flange 128 is disposed between the upstream or proximal segment and the downstream or distal segment. The radial flange 128 extends radially beyond the proximal segment 1222 and the distal segment 1242 to define a lower seat surface 126 to which a locking ring 180 can be secured. A hole 130 included in dispenser 120 is downstream (e.g., below) of the radial flange 128. That is, the hole 130 may be disposed in the distal segment 1242 and may extend from the outer surface 136 of the distal segment 1242 to the internal cavity 132.

[0069] In the depicted embodiment, the proximal segment 1222 is primarily cylindrical, but includes a ridge 1224 in which the axial hole 134 is formed. Other embodiments (such as those without the arc initiator 140) may not include the ridge 1224; however, when the proximal segment 1222 includes the ridge 1224, it may still be described herein as “generally cylindrical”, as the term is intended to indicate a generally cylindrical shape rather than a perfectly cylindrical one. The distal segment 1242 may also be generally cylindrical, but may have a wider outer radius than the proximal segment 1222 and may have a tapered inner surface 1324. Each of the features allows the dispenser 120 to engage additional components of the sub-box 100 to securely fasten the dispenser 120 relative to these additional components.

[0070] Specifically, the outer radius of the distal segment 1242 can be sized to be located close to the tip 150 (see...). Figure 7C The inner surface 1324 tapers within the dispenser seat 1542 defined by the distributor 120, providing a mating surface for the electrode 190 that can be located therein. The taper of the inner surface 1324 may also define an engagement shoulder of the electrode 190 at the distal end 124 of the dispenser 120, as described in further detail below. In the depicted embodiment, the inner surface 1324 is cylindrical above the aperture 130 and tapers below the aperture 130. Furthermore, in the depicted embodiment, the inner surface 1324 has a single linear taper. However, in other embodiments, the inner surface 1324 may define one or more ramps, whether linear, curved, or irregular, and / or the inner surface may define any other features (such as steps, etc.) that can help removably or non-removably attach the electrode 190 to the inner surface 1324. Additionally or alternatively, the inner surface 1324 may taper from any location and does not need to taper below the aperture 130.

[0071] Typically, dispenser 120 can be a non-conductive or insulating component. For example, dispenser 120 can be formed of rubber, plastic, synthetic materials, or combinations thereof. Therefore, dispenser 120 can contact the anode and cathode components of the cartridge and / or torch (such as tip 150 and electrode 190, etc.). Furthermore, in the depicted embodiments, consumables can be adapted for a single gas torch, and thus, in at least some cases, dispenser 120 can be referred to as gas dispenser 120.

[0072] Turn now Figures 7A to 7C In the depicted embodiment, tip 150 is an annular portion extending from a proximal or upstream end 154 to a distal or downstream end 168. An upstream or proximal segment 156 extends from the proximal end 154, and a downstream or distal segment 170 extends from the distal end 168. The proximal segment 156 and the distal segment 170 each surround or define an internal cavity 152 terminating in an orifice 172 defined by the distal segment 170. Furthermore, the proximal segment 156 typically includes features that direct fluid to different pathways for different purposes (e.g., plasma gas and protective gas), while the distal segment 170 typically includes features that cooperate with opposing surfaces of additional consumables (e.g., electrodes and protective caps) to define flow paths that concentrate fluid at or in a specific point or area (e.g., generating flow through a plasma chamber or concentrating protective gas).

[0073] More specifically, as described above, the proximal segment 156 defines a first set of holes 160 and a second set of holes 162. The first set of holes 160 extends from the outer surface 1562 of the proximal portion 156 to the inner surface 1564 of the proximal portion 156 to define a passageway into the inner cavity 152. In the depicted embodiment, the proximal portion 156 is generally cylindrical, and the holes 160 are disposed in arcuate recesses 158 extending inwardly into the outer surface 1562 of the cylindrical proximal portion 156. The recesses 158 can help alleviate the pressure differential at the entrance of the holes 160; however, in other embodiments, the proximal portion 156 may include recesses of different shapes, different sizes, etc., or may not need to include recesses 158.

[0074] Simultaneously, a second set of holes 162 is disposed on and extends through a radial flange 164 included in the proximal portion 156. The radial flange 164 extends axially from the distal outer portion of the proximal portion 156, but is radially spaced from the distal portion 170, such that a gap 166 is disposed between the radial flange 164 and the outer surface 176 of the distal portion 170. That is, the radial flange 164 extends beyond the tip or proximal end of the distal portion 170 and is concentric with the tip or proximal end of the distal portion 170, but is spaced from the outer surface 176 of the distal portion 170 to define the gap 166 therebetween. For example, in some embodiments, the radial flange 164 may be formed by undercutting at the distal end of the proximal portion 156, and therefore, the gap 166 may also be referred to as the undercut portion 166. Due to the gap / undercut portion 166, the second set of orifices 162 directs fluid to the outer surface 176 of the distal portion 170, rather than into the internal cavity 152 of the tip 150.

[0075] The distal portion 170 is shaped to smoothly guide the flow generated in the proximal portion 156 toward the workpiece. Specifically, the distal portion 170 includes a defined inner surface 175 that smoothly guides fluid toward the orifice 172. In different embodiments, the inner surface 175 may have different profiles, but in the depicted embodiment, the profile is a gentle concave ramp that generally matches the corresponding surface of the electrode 190 mounted in the tip (e.g., see...). Figure 2B Meanwhile, the outer surface 176 includes a concave profile 174 (used herein to refer to a surface that is curved, inclined, or otherwise contoured inward into the body of the component), which axially guides the gas to generate a flow of protective gas around the orifice 172 (see [link to documentation]). Figure 2B ).

[0076] See also Figures 7C to 7C The proximal portion 156 also includes or defines features that allow the tip 150 to be removably or non-removably coupled to additional consumable components (such as the dispenser 120 and locking ring 180). First, as described above, the radial flange 164 defines a lower seat surface 165 on which the locking ring 180 can be secured. Notably, the seat surface 165 does not extend from the outer surface 176 of the distal portion 170. Instead, the seat surface 165 is spaced apart from the outer surface 176 by a gap 166, and therefore the seat surface 165 does not disrupt or otherwise impact the flow surface defined by the outer surface 176 of the distal portion 170. Second, and as described above, the proximal end 154 defines a dispenser seat 1542 configured to receive the dispenser 120. That is, the proximal end 154 defines a dispenser seat 1542 having an inner diameter configured to match the outer diameter of the distal segment 1242 of the dispenser 120.

[0077] In at least some embodiments, tip 150 is a conductive component. Alternatively, tip 150 may include conductive portions. That is, tip 150 may be formed of or include components formed of conductive metals, metal alloys, or combinations thereof. This may be important because tip 150 may be an anode consumable in a set of consumables and may be conductive to initiate arcing. Additionally or alternatively, tip 150 may be conductive to facilitate scraping initiation and / or provide grounding during processing operations.

[0078] Turn now Figures 8A to 8C In the depicted embodiment, the locking ring 180 is another annular component and defines a generally cylindrical internal cavity 181. The locking ring 180 includes an upstream end 182, a downstream end 186, and a sidewall 184 extending from the upstream end 182 to the downstream end 186. As described above, the sidewall 184 includes an inner surface 1842 facing the outer surface of the dispenser 120 and the tip 150 to define an annular external axial channel 87 between the locking ring 180 and both the tip 150 and the dispenser 120 (see [link to original text]). Figure 2B (For example, to allow gas to flow from the orifice 130 in the distributor 120 to the first set of orifices 160 and the second set of orifices 162 in the tip 150).

[0079] The upstream end 182 of the locking ring 180 defines a first opening 1822 having a first diameter D1 (see...) Figure 8C The downstream end 186 defines a second opening 1862 having a second diameter D2 (see...). Figure 8C The first diameter D1 is sized to match the proximal section 1222 of the dispenser 120. Specifically, the first diameter D1 is sized such that the first end 182 can be mounted over the proximal section 1222 and engage the seat surface 126 defined by the radial flange 128 of the dispenser 120. Meanwhile, the second diameter D2 is sized such that the downstream end 186 is aligned with the seat surface 165 defined by the radial flange 164 of the tip 150. Specifically, the second diameter D2 allows the downstream end 186 to engage the radial flange 164 without covering the gap 166 formed between the radial flange 164 and the distal portion 170 of the tip 150. Therefore, in the depicted embodiment, the second diameter D2 may be larger than the first diameter D1.

[0080] The overall dimensions of the locking ring 180 allow the ends 182 and 186 of the locking ring 180 to tightly engage the corresponding seat surfaces 126 and 165 of the dispenser 120 and tip 150, respectively. This tight engagement securely holds the tip 150 and dispenser 120 in place within the locking ring 180. That is, the engagement ensures that the dispenser 120 and tip 150 remain stationary within a set of consumables (such as sub-cassette 101, sub-cassette 100, or consumable cassette 80, etc.). Additionally, in some embodiments, the tight engagement created by the upstream end 182 and the downstream end 186 can seal the axial external channel 87 formed within the locking ring 180 (see [link to documentation]). Figure 2B ).

[0081] More specifically, the locking ring 180 can be sealed against the dispenser 120 by compressing a material, which can be formed of an insulating material (e.g., plastic, rubber, or a combination thereof) with at least some elasticity. Alternatively, both the tip 150 and the locking ring 180 can be conductive components formed of metal (or any other conductive material), and a seal can be formed by compressing the conductive material against each other. This also electrically connects the locking ring 180 to the tip 150, such that, for example, the locking ring 180 can conduct electricity between the torch and the tip 150. However, in some embodiments, portions of the upstream end 182, the downstream end 186, the seat surface 126, and / or the proximal portion 156 may also include sealing elements, such as O-rings or portions thereof, which improve the seal between the locking ring 180 and the tip 150 and / or between the locking ring 180 and the dispenser 120 (but do not prevent conductivity between them).

[0082] See also Figures 8A to 8C In the depicted embodiment, the opening 1822 is not a perfect circle, but includes a groove 1824. The groove 1824 is configured to mate with a ridge 1224 formed in the proximal section 1222 of the dispenser 120. However, it is noteworthy that the groove 1824 and the ridge 1224 not only provide space for the axial bore 134 (for the trigger 140), but also, in addition, these features lock the dispenser 120 into a specific orientation within the locking ring 180 and prevent rotation of the dispenser 120 relative to the locking ring 180. Thus, the ridge 1224 and the groove 1824 ensure that the dispenser 120 is stationary within the locking ring 180. Furthermore, in the depicted embodiment, the upstream end 182 may include a mark 188, and the groove 1824 helps align the mark 188 in a specific location, allowing it to be identified via any technology now known or developed in the future (e.g., via optical recognition).

[0083] Although not shown, in at least some embodiments, the downstream opening 1862 of the locking ring 180 and the radial flange 164 of the tip 150 may also include similar keying features to align and rotatably secure the tip 150 within the locking ring 180. Alternatively, the tight engagement between the tip 150 and the locking ring 180 may be sufficient to prevent rotation of the tip 150, or the tip 150 may be free to rotate relative to the locking ring 180 but may be fixed in all other degrees of freedom (e.g., such that the tip 150 may rotate about a central axial axis but may not translate axially, laterally, tilt, or otherwise move).

[0084] Turn now Figures 9A to 9C Example electrode 190 is described, which may be non-removably included in a case (such as consumable case 80 or sub-case 100, etc.) or removably coupled to a case (such as sub-case 101, etc.). Electrode 190 extends from a proximal end 192 to a distal end 194, the distal end including a radioactive insert 1942 (or a cavity defining a radioactive insert 1942), such as a hafnium insert. A proximal portion 193 extends from the proximal end 192, a distal portion 196 extends from the distal end 194, and a shoulder 198 extends radially outward between the proximal and distal portions.

[0085] Typically, electrode 190 is formed of a conductive material and is configured to connect to a cathode element in the torch and receive a negative potential. Thus, when electrode 190 is spaced from a positively charged (and / or grounded) tip 150, an arc may be induced between electrode 190 and tip 150, as described in further detail below. The proximal portion 193 and the distal portion 196 may each be primarily cylindrical, but may include chamfered or tapered edges that smooth the transition to their respective ends. A smooth transition to the proximal end 192 allows for easy connection of the proximal end 192 to the cathode element of the torch, while a smooth transition to the distal end 194 allows for easy access to the plasma chamber (e.g., Figure 2B The flow path of the plasma chamber 92 and / or the orifice 172 surrounding the electrode 190 toward the tip 150 is smooth.

[0086] The shoulder 198 of the electrode 190 allows the electrode 190 to be securely located within the dispenser 120, and in at least some embodiments, the electrode 190 can be non-removably secured within the dispenser 120. For example, in the depicted embodiment, the shoulder 198 includes a first step 1982, a second step 1984, and a third step 1986. The first step 1982 extends radially beyond the proximal portion 193, while the second step 1984 extends radially beyond the first step 1982 and tapers toward the third step 1986. That is, the top or proximal end of the second step 1984 has a diameter larger than that of the first step 1982, but tapers to a smaller diameter at its bottom end (it can be smaller, larger, or equal to the diameter of the first step 1982). The third step 1986 then extends radially beyond the second step 1984 and tapers toward the distal portion 196. Therefore, all three steps in steps 1982, 1984, and 1986 define a rigid upper edge that can prevent longitudinal movement (e.g., upward movement) in the proximal direction when abutting against a wall or surface.

[0087] See also Figures 9A to 9C But now combined Figure 2B and Figures 6A to 6C As a specific example, if the third step 1986 is positioned below the distal end 124 of the dispenser 120, the tapering of the converging inner surface 1324 of the dispenser 120 can converge to define an opening having a diameter smaller than the diameter of the upper edge of the third step 1986. That is, the tapered inner surface 1324 of the dispenser 120 and the third step 1986 of the electrode 190 can cooperate to form a pawl-like engagement. Simultaneously, the second step 1984 can engage the tapered inner surface 1324 of the dispenser 120 and prevent the electrode 190 from moving longitudinally in a distal direction (e.g., downwards). This also seals the bottom of the internal cavity 132 of the dispenser 120 to prevent fluid F from flowing directly from the internal cavity 132 of the dispenser into the internal cavity 152 of the tip 150.

[0088] In some embodiments, the engagement between the shoulder 198 of the electrode 190 and the inner surface 1324 of the dispenser 120 can non-removably secure the electrode 190 within the dispenser 120. For example, the electrode 190 may be press-fitted to engage with the dispenser 120, and the electrode 190 cannot be removed from the dispenser 120 without damaging the dispenser 120 and / or the electrode 190. However, in other embodiments, the engagement between the shoulder 198 of the electrode 190 and the inner surface 1324 of the dispenser 120 may allow the electrode 190 to be removably mounted within the dispenser 120 (e.g., by pressing the electrode 190 by hand and by pulling it out by hand). Embodiments with removably mounted electrodes 190 can be particularly useful if the lifespan of the electrode 190 is significantly shorter than that of other consumables in a set of consumables (e.g., if the tip lifespan is twice that of the electrode). However, the non-removable mounting of electrode 190 ensures that electrode 190 is securely connected to other components and properly aligned relative to them, which can maximize the lifespan of electrode 190.

[0089] Furthermore, as mentioned, electrode 190 is only one example electrode that can be used with the consumables presented herein, and in at least some embodiments, other consumables presented herein (such as consumables forming sub-cassette 101, etc.) can be used with a wide variety of electrodes. Other embodiments of electrode 190 may include various features that allow electrode 190 to be secured within dispenser 120 (removably or non-removably), may have different sizes or shapes, and / or may include one or more radioactive inserts in any configuration.

[0090] Second Consumable Box

[0091] Turn now Figures 10 to 13E These figures depict one or more components included in sub-box 200. As described above, in the depicted embodiment, sub-box 200 includes a shield 210 and a shield cup 240. These components may be manufactured independently and non-removably coupled together to form sub-box 200 or otherwise formed as a single unitary box 200. Alternatively, these components may be individually packaged and removably coupled to each other. For illustration purposes, Figure 10 An exploded view of the components included in sub-box 200 is provided. Figure 11 A sectional view of the assembled sub-box 200 is provided. Figures 12A to 13E A single component that can be used to form sub-box 200 is depicted.

[0092] More specifically, Figure 10 and Figure 11An embodiment is illustrated in which the shield 210 is non-removably coupled to the shield cup 240 by securing an engagement member 219 of the shield 210 into a corresponding recess 278 included on the shield cup 240. However, in other embodiments, the engagement member 219 and the recess 278 may be configured to allow removable coupling, or may be replaced by structural elements that allow removable coupling. For example, the engagement member 219 may include threads that removably engage the recess 278. Regardless of whether the shield 210 and the shield cup 240 are non-removably coupled or removably coupled together, the shield 210 and the shield cup 240 may also define other features for alignment and mating of the shield 210 and the shield cup 240. For example, in the depicted embodiment, the inner surface 213 of the shield 210 defines a shoulder 232, which engages the shoulder 232 at the distal end 2402 of the shield cup 240 when the shield 210 and the shield cup 240 are coupled together.

[0093] In any case, the shield 210 extends from proximal end 218 to distal end 216, and the shield cup 240 extends from proximal end 2401 to distal end 2402. The proximal end 218 of the shield 210 engages with the distal end 2402 of the shield cup 240 (e.g., via engaging member 219 and groove 278) to form a generally converging shield that covers the sub-box 100 (e.g., see...). Figure 2A , Figure 2B and Figure 3 That is, the shield cup 240 is an annular component formed around the internal cavity 2403, and the shield 210 is an annular component formed around the internal cavity 228 (and the outlet orifice 214), and the internal cavities 228 and 2403 can form an internal space that is sized to receive most of the sub-box 100. Therefore, when the sub-box 100 and sub-box 200 are connected to the torch body (e.g., torch body 52 or 62), the sub-box 200 can protect the sub-box 100 from splashes generated during the processing operation (while the outlet orifice 214 provides space for the protective gas, plasma gas, and arc required for the processing operation to exit the sub-box 200).

[0094] See also Figure 10 and Figure 11 As described above, in at least some embodiments, sub-box 200 may be mechanically and electrically connected to the torch body (e.g., torch body 52 or 62). In fact, in some embodiments, sub-box 200 may only provide a mechanical connection to the torch, and sub-box 100 may be coupled to the torch via sub-box 200. That is, in some embodiments, sub-box 100 may be mechanically connected to or located within sub-box 200, and sub-box 200 may be mechanically connected to the torch to connect sub-box 100 to the torch. As described above, to provide such a connection, shield cup 240 includes a first conductor 242 and a second conductor 252 extending from the proximal end 2401 of shield cup 240, each of which is further described in detail below.

[0095] Consumable parts

[0096] Turn now Figures 12A to 12C The shield 210 converges generally from its proximal end 218 toward its distal end 216 (e.g., toward the outlet orifice 214). More specifically, the shield 210 includes an outer surface 211 and an inner surface 213, which converge generally over the proximal portion 220 of the shield 210 (which extends from the distal end 216). For example, in the depicted embodiment, the outer surface 211 includes a converging surface 224 having a constant slope extending between a cylindrical surface 222 and a flat surface 226. Meanwhile, the inner surface 213 converges generally toward the orifice 230 but is defined for a shoulder 232 for the shield cup 240, as described above. Thus, when the sub-cassette 100 is mounted in the sub-cassette 200, the inner surface 213 of the shield 210 can cooperate with the outer surface 176 of the tip 150 to direct fluid F toward the orifice 230 and / or the outlet 214 (e.g., along a first fluid path 88, such as...). Figure 2B (As shown) guide. By comparison, the distal portion 212 of the shield 210 is generally cylindrical, and an outlet orifice 214 is defined at the distal end 216 of the shield 210.

[0097] The outlet orifice 214 is typically sized such that gas exiting from sub-box 100 and / or an arc extending from sub-box 100 can travel through the outlet orifice 214 to the workpiece without contacting sub-box 200. However, not all gas exiting sub-box 100 travels through the outlet orifice 214. Instead, some protective gas (e.g., along...) Figure 5 The gas flowing through the second fluid path protection section 116 can exit the shield via the orifice 230, which allows the protective fluid to exit the internal cavity 228 of the shield 210. In the depicted embodiment, the orifice 230 is formed in the flat surface 226 such that the orifice 230 generates a stream of gas flowing in approximately the same direction (e.g., vertically downward) as the gas exiting the outlet orifice 214. That is, the orifice 230 can be parallel to the outlet orifice 214.

[0098] Turn now Figure 13A and Figure 13B In the depicted embodiment, the shield cup 240 includes a first conductor 242, a second conductor 252, and an insulating sleeve 260. As in... Figure 13BAs best seen, a first conductor 242 extends through a channel 2664 formed in an insulating sleeve 260, while a second conductor 252 is located on the inner surface 264 of the insulating sleeve 260. At least a portion of the insulating sleeve 260 is disposed between the inner surface 264 and the channel 2664, and thus the insulating sleeve 260 insulates the first conductor 242 from the second conductor 252. Therefore, the first conductor 242 can form an electrical connection for a first component, while the second conductor 252 can form a separate and independent electrical connection for a second component. For example, in the depicted embodiment, the first conductor 242 can ground the shield 210, while the second conductor 252 grounds and / or provides a positive potential to the tip 150 included in the sub-casing 100 mounted within the sub-casing 200 (e.g., via a locking ring 180).

[0099] Figure 13C A first conductor 242 and a second conductor 252 are depicted without the insulating sleeve 260. As can be seen, at one end, the first conductor 242 includes a flange 244 that can be mechanically and electrically connected to a corresponding feature included in the torch body (e.g., via partial rotation). The flange 244 is connected to the ring member 248 via an elongated member 246. The elongated member 246 can extend through a channel 2664 included in the insulating sleeve 260, while the ring member 248 provides an annular electrical connector that can mate with the proximal portion 220 of the shield 210 to ground the shield 210. In the depicted embodiment, the ring member 248 includes a gap 2482 that allows the ring member 248 to be connected to the insulating sleeve 260, as described in further detail below.

[0100] The second conductor 252 also includes one or more flanges similar to the flanges 244 included on the first conductor 242. For example, in the depicted embodiment, the second conductor 252 includes two flanges 254. Thus, in general, the first conductor 242 and the second conductor 252 can provide three mechanical connection points at which the sub-casing 200 can be secured to the torch body, ensuring that the mechanical connection is stable and holding the sub-casing 200 (or consumable casing 80, consumable casing 80', etc.) in a fixed position. The two flanges 254 also provide redundancy for the electrical connection provided by the flanges 254, which may be important for ensuring that the casing with the shield cup 240 can strike an arc. However, in other embodiments, the first conductor 242 does not need to include two flanges 254 and may include one flange 254 or three or more flanges, and these flanges may differ from those depicted in the figures.

[0101] In the depicted embodiment, flange 254 extends from the top edge 2562 of cylindrical member 256. The top edge 2562 also defines a notch 2564 configured to align with a channel 2664 of insulating sleeve 260, ensuring that the second conductor 252 does not contact the first conductor 242 when mounted in channel 2664. Similarly, bottom edge 2566 is spaced apart from the annular member 248 of the first conductor 242. Thus, the second conductor 252 and the first conductor 242 provide independent and separate conductive paths. Additionally, cylindrical member 256 is annular to define an internal cavity 258 that defines at least a portion of the internal cavity 2403 of shroud cup 240.

[0102] Figure 13E An insulating sleeve 260 without a first conductor 242 and a second conductor 252 is depicted. The insulating sleeve 260 includes a relatively flat or planar top surface 262 that can rest against a corresponding flat or planar surface of the torch body (e.g., torch body 52 or 62) when a set of consumables, including a shield cup 240, is mounted on the torch body. In the depicted embodiment, the top surface 262 is defined by an outer edge 268 that provides a grip for the user when the shield cup 240 (or the entire consumables box, such as consumable box 80 or sub-box 200, etc.) is attached to or removed from the torch body.

[0103] As mentioned, the insulating sleeve 260 includes an inner surface 264 sized to receive the second conductor 252. In the depicted embodiment, the inner surface 264 also includes features that allow the second conductor 252 to sit flush against the inner surface 264. Specifically, the inner surface 264 includes a first groove 2642 shaped to receive a cylindrical member 256 (including a notch 2564) of the second conductor 252 and a second groove 2666 shaped to receive a flange 254. Meanwhile, the outer surface 270 of the shield cup 240 is shaped and sized to be located within and / or engage the shield 210 and the first conductor 242. For example, in the depicted embodiment, a flange 276 extends from the bottom surface 274 of the insulating sleeve 260. The flange 276 is sized and positioned to engage a gap 2482 included in the annular member 248 of the first conductor 242.

[0104] Arc triggering

[0105] exist Figures 2A to 13EIn the embodiment depicted, the arc initiator 140 is a fixed element that is secured within the distributor 120 and extends into the gap between the tip 150 and the electrode 190. The arc initiator 140 may be connected to a negative potential, such as the same power as that connected to the electrode 190, but positioned closer to the tip 150 than the electrode 190. Therefore, an arc can strike between the arc initiator 140 and the tip 150, where the power is less than that required to strike an arc between the electrode 190 and the tip 150 (e.g., where the pulse is less than that required for a conventional high-frequency initiation). Once an arc is struck between the arc initiator 140 and the tip 150, a gas flow (e.g., along a second fluid path 90, such as...) Figure 2B As shown, the arc can be transferred to the electrode 190 and the tip 150 before it is finally blown out of the tip 150 and leaves the orifice 172 defined by the tip 150.

[0106] However, due to the size and functionality of the arc initiator 140, precise alignment between the tip 150 and the electrode 190 may be required. Therefore, incorporating the arc initiator 140 into a single, integrated case (i.e., a case with non-removable, non-repairable parts) ensures proper orientation of the arc initiator 140. Furthermore, if the case containing the consumables presented herein includes a stationary arc initiator 140, the entire case (e.g., consumable case 80 or sub-case 100) can be fixed and stationary. That is, with a stationary arc initiator 140, the case (such as consumable case 80, etc.) may not include any moving parts, which can extend the case's lifespan. However, in some embodiments, the arc initiator 140 does not need to be stationary, but the remainder of the consumables can be allowed to remain stationary, and thus the overall lifespan of the case can still be extended. For example, the arc initiator 140 may be formed of a shape memory alloy that moves to contact and disengage from the tip 150 and / or electrode 190 to induce an arc between the tip and the electrode. Alternatively, the arc initiator 140 may be combined with the following Figures 14 to 20 One of the alternative arc initiators under discussion is a replacement.

[0107] Turn now Figures 14 to 20 In general, these figures illustrate additional arc initiation techniques that can be used with the consumables and cases presented herein, or at least certain embodiments of the consumables and cases presented herein. For simplicity, these techniques are described with respect to the consumables discussed above, where possible. However, such description is not intended to limit these techniques to the consumables discussed herein. In fact, many of the initiation techniques presented herein replace the arc initiator 140, while also requiring one or more of the consumables discussed above to be modified and / or supplemented with additional components. Therefore, in Figures 14 to 20In the figures, components that may be substantially similar to the consumables presented above (e.g., dispenser 120, tip 150, locking ring 180, electrode 190, etc.) are marked with the same reference numerals, even though such parts may differ between the figures.

[0108] first, Figure 14 A technique for pressure-actuated initiation of an electric arc within a housing 500 is schematically depicted. In this embodiment, an initiator 502 is disposed around or adjacent to an electrode 190, between a distributor 120 and a tip 150. The initiator 502 is conductive and is initially positioned to contact both the electrode 190 and the tip 150, thereby completing the circuit between them. However, the initiator 502 is longitudinally movable relative to the electrode 190, with the tip 150 defining a downstream boundary for longitudinal movement and the distributor 120 defining an upstream boundary for longitudinal movement. Thus, pressure can be used to move the initiator 502 from a contact position to a separated position, and specifically to separate the initiator 502 from the tip 150, to induce pilot arcing between the tip 150 and the electrode 190, which initiates the processing operation.

[0109] More specifically, the housing 500 may define fluid passages into the upstream chamber 504 above the initiator 502 and the downstream chamber 506 below the initiator 502. For example, in Figure 2B In the depicted arrangement, the initiator 502 may be positioned on the second fluid path 90, and the tip may include additional features (e.g., orifices and walls / flanges) to define chambers 504, 506. However, for simplicity, in Figure 14 In the diagram, fluid flowing through distributor 120 is shown entering chamber 504, and locking ring 180 is depicted having an opening 582 leading to downstream chamber 506.

[0110] Regardless of how chambers 504 and 506 are defined, pressurized chamber 504 moves the initiator 502, which is in continuous contact with electrode 190, to contact tip 150. That is, pressurized chamber 504 "sets" or prepares the initiator 502 for arc initiation by moving the initiator to a contact position with electrode 190 and tip 150. Then, if chamber 506 is pressurized while the initiator 502 is in its contact position, the initiator 502 will move away from tip 150 (e.g., upwards), simultaneously drawing an arc and initiating the machining operation. However, in other embodiments, the initiator may remain in contact with tip 150 instead of electrode 190 and still draw an arc when moving from the contact position to a separation position away from electrode 190.

[0111] In the depicted embodiment, cartridge 500 is coupled to a gas source via a conduit assembly including two valves: valve 510 and valve 520. Thus, in the depicted embodiment, chamber 504 is pressurized by opening valve 520 and closing valve 510, while chamber 506 is pressurized by opening valve 510 and closing valve 520. Additionally or alternatively, valve 520 may open to a discharge position when chamber 506 is pressurized to reduce the amount of pressure required to move initiator 502 in chamber 506. In either case, in at least some embodiments having this valve arrangement, the valves can be operated by an electrical signal generated in response to trigger actuation. For example, trigger-activated actuation may open valve 510 and close valve 520 (possibly after a temporary opening of valve 520, where valve 510 is either open or closed), and trigger-deactivated actuation may open valve 520 and close valve 510.

[0112] However, the aforementioned valve arrangement and control arrangement are merely examples, and in other embodiments, any combination of flow paths, valve arrangements, or features now known or developed hereafter for controlling pressurization can be used to generate the pressure for driving the initiator 502. Similarly, any pressurization feature or component can be controlled with any desired control arrangement / logic. Furthermore, in some embodiments, the cartridge does not need to include the initiator 502, and the electrode 190 or a portion thereof can be driven to contact and disengage from the tip 150 by pressure changes.

[0113] Next, Figure 15 A technique for initiating an electric arc within a cartridge 600 using mechanical actuation is schematically depicted. Similar to cartridge 500, cartridge 600 includes a conductive initiator 602 disposed around electrode 190 between dispenser 120 and tip 150, but now the initiator 602 is pushed in one direction by pressure and pushed in the opposite direction by an elastic member 610 included in the operating end of torch body 52 mounted on cartridge 600 (however, reference numeral 52 is used only as an example, and torch body may also represent torch body 62).

[0114] More specifically, when the housing 600 is disconnected from the torch body 52, the initiator 602 can "float" on the electrode 190, "floating" within a range intended to indicate that the initiator 602 can move freely along the electrode 190. Then, when the housing 600 is mounted onto the torch body (such as torch body 52), the elastic member 610 included in the torch body 52 can engage the initiator 602 and push the initiator into contact with the tip 150 (e.g., downwards), such that the initiator 602 completes the circuit between the tip 150 and the electrode 190. Then, in order to ignite an arc, a fluid (e.g., process gas) can be introduced into a region 604 below the initiator 602 until the pressure in region 604 overcomes the thrust exerted by the elastic member 610, causing the initiator 602 to move out of contact with the tip 150 (e.g., moving the initiator 602 upwards and initiating an arc between the tip 150 and the electrode 190). When fluid is no longer delivered to region 604, the pressure will dissipate, and the elastic member 610 will move the initiator 602 back into contact with the tip, making the cartridge 600 ready for another initiation.

[0115] exist Figure 15 In the schematic diagram, fluid can enter region 604 through an opening in tip 150 downstream of locking ring 180; however, this is merely an example provided for simplicity. As another example, in Figure 2B In the arrangement shown, the tip 150, distributor 120, and / or electrode 190 can be modified such that the fluid F actuating initiator 602 traversing the second fluid path 90. Furthermore, in this example, the elastic member 610 can extend through the axial bore 134 instead of the arc initiator 140 (and / or the distributor 120 can be further modified).

[0116] Turn now Figure 16A and Figure 16B These figures schematically depict techniques for inducing an electric arc within a cell using magnetic actuation. Specifically, Figure 16A and Figure 16B A box 700 with an initiator 702 formed of or comprising a magnetic material is schematically depicted. The initiator 702 is similar to initiators 502 and 602, except that the initiator 702 can be moved from a contact position between the initiator contact tip 150 and the electrode 190 to a spaced or separated position to induce an arc between the tip 150 and the electrode 190. However, now, the initiator 702 is moved by magnetic actuation (rather than by pressure actuation generated by an elastic member or mechanical actuation).

[0117] Specifically, the magnet 710 in the torch body 52, on which the housing 700 is mounted, can cause the initiator 702 to be in contact position P1 ( Figure 16A (An example is shown in the image) and the separation position P2 ( Figure 16BThe torch body 702 moves between points 150 and 190 (however, again, reference numeral 52 is used only as an example, and the torch body may also represent torch body 62). When the upstream pole of the initiator 702 is the same as the downstream pole of the torch magnet 710 (e.g., both are negative), the torch magnet 710 will repel the initiator 702 and move the initiator 702 to its contact position P1. Alternatively, when the upstream pole of the initiator 702 is opposite to the downstream pole of the torch magnet 710 (e.g., one positive and one negative), the torch magnet 710 will attract the initiator 702 and move the initiator 702 to its separation position P2. Moving the initiator 702 from its contact position P1 to its separation position P2 induces an arc between the tip 150 and the electrode 190 and starts the torch.

[0118] In some embodiments, the magnet 710 can be drawn from the repulsion initiator 702 ( Figure 16A The first configuration C1 is physically redirected to the attraction initiator 702. Figure 16B The second configuration C2. For example, magnet 710 can rotate about its center. Reorientation of magnet 710 can cause initiator 702 to move linearly or rotationally between its contact position P1 and its separation position P2, which need not be... Figure 16A and Figure 16B The precise location depicted (e.g., if reorientation causes rotation of the initiator 702). Alternatively, the magnetic poles of the torch magnet 710 can be reversed, such as by using an electromagnet as the torch magnet 710 and reversing the direction of the current passing through the electromagnet.

[0119] As a more specific example, in some embodiments, the torch magnet 710 may include an electromagnet having two windings extending in opposite directions. Upon startup, current may briefly flow downwards along one of the windings to orient the magnetic poles of the torch magnet 710 to configuration C1, which repels the initiator 702 to contact position P1. Current is then switched to the second winding, reversing the magnetic pole configuration of the torch magnet 710 to configuration C2 and moving the initiator 702 from contact position P1 to separation position P2, thereby drawing out an electric arc.

[0120] In fact, in at least some embodiments, a pilot current can flow through the winding to avoid interference that might arise from using an electromagnet circuit separate from the cutoff current. The first winding can be connected back to the power source, and the second winding can be connected to either tip 150 or electrode 190, such that current is delivered to either tip 150 or electrode 190 when the initiator 702 moves from the contact position P1 to the separation position P2. If the main power line (or a portion thereof) extends through the latter winding (which causes the initiator to move to the separation position P2), the magnet 710 will remain in the separation position P2 when the arc is ignited. However, if the pilot current flows through the latter winding, air pressure can be used to keep the initiator 702 returning until a new arc is required.

[0121] It is worth noting that, in Figure 16A and Figure 16B The diagram shows an initiator 702 in continuous contact with an electrode 190 (e.g., a cathode). However, in other embodiments, the initiator 702 may be in continuous contact with the tip 150. Furthermore, although the initiator 702 is depicted as sliding, it is not necessary for it to slide, and as mentioned, in some embodiments, it may rotate or otherwise move without sliding. Further still, in other embodiments, the consumable assembly does not necessarily include an initiator 702 formed of or comprising magnetic material, and instead, the electrode 190 or tip 150 may be removable and formed of or comprising magnetic material. In such embodiments, the magnet 710 may attract the electrode 190 away from the tip 150 to initiate an arc, repel the tip 150 away from the electrode to initiate an arc, attract the tip 150 until it is blown away from the electrode 190 by a process gas to initiate an arc, or generate any other repulsion or attraction that allows the tip 150 and electrode 190 to separate and initiate an arc.

[0122] As another alternative, Figure 17 The technique for initiating an electric arc within a housing 800 using a pivotable arc initiator 802 and a flow barrier 810 is schematically depicted. The initiator 802 is positioned similarly to the arc initiator 140, but is now connected to the distributor 120 via a pivoting connection 804. Thus, the initiator 802 can freely oscillate back and forth between the contact tip 150 and the contact electrode 190. The flow barrier 810 is positioned upstream of the initiator 802 and has a geometry adjusted such that alternating vortices 812, similar to the wake of a von Kármán vortex street, are discharged when the pressure of the fluid flow F across the barrier 810 reaches an ideal level for arc maintenance. The oscillating vortices 812 cause the initiator 802 to oscillate back and forth, alternately contacting the tip 150 and the electrode 190, which in turn induces an electric arc.

[0123] In some embodiments, the housing 800 may further include a nest 806 that may lock the initiator against or in place between the tip 150 and the electrode 190 during cutting. For example, as the flow rate of the fluid F increases after induction (e.g., during cutting), pressure may draw the initiator 802 forward into the nest 806, which will keep the initiator 802 stable during cutting to avoid accidental contact with the tip 150. Additionally or alternatively, in some embodiments, the initiator 802 may itself form a flow barrier to generate alternating discharge vortices from its own wake (e.g., in the absence of the barrier 810), thereby causing oscillating drag loads and oscillating motion.

[0124] Turn now Figure 18 In some embodiments, the consumables and cases presented herein do not necessarily include a dedicated arc initiator and can initiate an arc via scraping. In such embodiments, tip 150 may be grounded and in contact with workpiece 902 having a positive potential, which can induce an arc between the electrode in case 900 and workpiece 902 (as shown at position 2). In some cases, scraping may cause an arc to temporarily extend between tip 150 and electrode 190; however, tip 150 does not cause arc initiation, and the contact between workpiece 902 and case 900 causes arc initiation.

[0125] Figure 19 and Figure 20 Another technique for initiating an arc within a cartridge is illustrated. In at least some embodiments, these techniques allow for the movement of electrodes within the cartridge. However, the electrodes may still be non-removably fixed within the cartridge and / or non-removably coupled to additional consumable components. Alternatively, the aforementioned techniques can be used with embodiments that provide electrodes independent of the cartridge, such as embodiments that allow electrode 190 to be removably coupled to sub-cartridge 101. While the electrodes may not be stationary in these embodiments, cartridges including or connected to movable electrodes still address end-user inventory and assembly issues. That is, cartridges including or connected to movable electrodes can still be connected to the torch with a single action, eliminating the need for users to maintain a wide variety of consumable inventory. Furthermore, embodiments configured to perform these techniques may be more robust than consumable assemblies that use more fragile components (such as springs) to create consumable movement.

[0126] In other words, Figure 19In the torch 50, the housing 1000 includes an electrode 190, which is connected to the trigger 58 of the torch 50 when the housing 1000 is mounted on the torch body 52. ​​Specifically, the electrode 190 is connected to the trigger 58 via a link 1002. The link 1002 is configured to pull the electrode 190 upward away from the tip 150 in response to actuation of the trigger 58 (i.e., in response to a pull / press of the trigger). This upward movement induces an arc between the tip 150 and the electrode 190 and ignites the torch. However, Figure 19 This is merely one example of arc initiation triggered by a linkage, and in other embodiments, the linkage or a series of linkages may move the tip 150, the initiator (e.g., initiators 502, 602, 702, etc.), or any combination of these components to induce an arc between the tip 150 and the electrode 190 and / or induce an arc that can be transferred to the tip 150 and the electrode 190.

[0127] In contrast, Figure 20 In this embodiment, housing 1050 includes a sealed fluid chamber 1052 upstream of electrode 190. Fluid chamber 1052 continuously applies downstream pressure to electrode 190, forcing electrode 190 into contact with tip 150 until a force resists this downstream pressure is achieved. Specifically, during the delivery of process gas toward the plasma chamber, a pressure stronger than that in fluid chamber 1052 is generated in the plasma chamber. This plasma chamber pressure causes electrode 190 to separate from tip 150, thereby inducing an arc between the electrode and the tip. Advantageously, such a technique also allows the gap size between tip 150 and electrode 190 to be correlated with gas pressure, which keeps electrode 190 closer to tip 150 and reduces arc stretching at lower pressures.

[0128] While the consumables presented herein have been illustrated and described in detail with reference to specific embodiments thereof, they are not intended to be limited to the details shown, as various modifications and structural changes that may be made herein will be apparent without departing from the scope of the invention and within the scope and protection of the equivalents of the claims. For example, as mentioned, the consumables presented herein can be modified to connect to or be used with any other desired consumable or non-consumable component, including to facilitate specific arc initiation techniques. Furthermore, the consumables presented herein can be adapted for automated (e.g., mechanized) and / or manual (e.g., handheld) cutting.

[0129] Furthermore, various features from one embodiment of the embodiments may be combined with those from another embodiment. That is, the disclosure set forth above is considered to encompass multiple different inventions with independent practical applicability. While each of these inventions has been disclosed in its preferred form, the specific embodiments disclosed and illustrated herein should not be considered limiting, as many variations are possible. The subject matter of the invention includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions, and / or characteristics disclosed herein. Therefore, it is appropriate that the appended claims be interpreted broadly and in a manner consistent with the scope of protection set forth in the appended claims.

[0130] It should also be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “inner,” “outer,” “next,” and “external,” as may be used herein, describe reference points only and do not limit the invention to any particular orientation or configuration. Furthermore, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary should not be construed as a preferred or advantageous embodiment, but rather as an example or illustration of a possible embodiment of the invention. Additionally, it should be understood that the consumables described herein, or portions thereof, can be manufactured from any suitable material or combination of materials, such as plastics or metals (e.g., copper, bronze, hafnium, etc.) and their derivatives and combinations thereof.

[0131] Finally, when used herein, the term “comprises” and its derivatives (such as “comprising”, etc.) should not be understood in an exclusionary sense; that is, these terms should not be interpreted as excluding the possibility that the described and defined elements, steps, etc., may include. Similarly, in any description listing “a” or “a first” element or its equivalent, the disclosure should be understood to include a combination of one or more of that element, neither requiring nor excluding two or more of that element. Meanwhile, when used herein, the term “approximately” and its family of terms (such as “approximate”, etc.) should be understood to indicate values ​​very close to those accompanying the aforementioned terms. That is, deviations from precise values ​​within reasonable limits should be accepted, as those skilled in the art will understand that such deviations from the indicated values ​​are unavoidable due to measurement inaccuracies, etc. For example, the term “approximately” can indicate a tolerance of plus or minus 0.002 inches, 0.001 inches, or up to 0.005 inches. This also applies to the terms “about” and “around” and “substantially”.

Claims

1. A consumable kit for a plasma arc torch, comprising: A dispenser that defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser; The nozzle includes: A first set of channels extends from the internal cavity of the nozzle to the external surface of the nozzle; and A second set of channels extends from the outer surface of the nozzle to the undercut portion of the nozzle; A locking ring, configured to secure the dispenser to the nozzle in a non-removable manner; and A static arc initiator is located in the distributor and positioned to extend into the gap between the nozzle and an electrode disposed within the nozzle.

2. The consumable group as claimed in claim 1, wherein, The electrode is connected to the dispenser in a way that cannot be removed.

3. The consumable group as claimed in claim 1, wherein, The nozzle includes a proximal portion and a distal portion, and the first set of channels and the second set of channels extend through the proximal portion.

4. The consumable group as claimed in claim 3, wherein, The distal portion defines an orifice that provides an outlet from the internal cavity of the nozzle, wherein the first set of channels defines a gas passage to the orifice, and wherein the second set of channels defines a gas passage that allows gas to flow across the outer surface of the distal portion and around the orifice.

5. The consumable group as claimed in claim 3, wherein, The undercut portion extends longitudinally into the bottom surface of the proximal portion of the nozzle.

6. The consumable group as claimed in claim 1, wherein, The dispenser defines an upper shoulder, the nozzle defines a lower shoulder, and the locking ring further includes: The upstream end is configured to engage the upper shoulder; and Downstream end, which is configured to engage the lower shoulder.

7. The consumable group as claimed in claim 6, wherein, The upstream end defines a first opening with a first diameter, and the downstream end defines a second opening with a second diameter, wherein the first diameter is smaller than the second diameter.

8. The consumable group as claimed in claim 6, wherein, The lower shoulder of the nozzle defines the boundary of the undercut portion, and the downstream end of the locking ring is configured to extend beyond the lower shoulder to the boundary.

9. The consumable group as claimed in claim 1, wherein, The nozzle has a proximal limiting seat, and the locking ring is configured to compress the dispenser into the seat.

10. The consumable group of claim 1, further comprising: A protective cup, configured to mechanically connect the consumable assembly to the operating end of the torch and electrically connect the nozzle to an electrical conductor in the torch.

11. A consumable group for a plasma arc torch, comprising: A dispenser that defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser; Electrodes, which are disposed within the distributor and are fixedly coupled to the distributor in a non-removable manner; A nozzle defining at least one set of channels that guides gas into a gap defined between the electrode and the nozzle, the nozzle being non-removably and fixedly coupled to the distributor; as well as A static arc initiator, which is located in the distributor and positioned to extend into the gap between the electrode and the nozzle.

12. The consumable group of claim 11, further comprising: A locking ring extends around the proximal end of the dispenser and the distal end of the nozzle to non-removably and securely couple the dispenser to the nozzle.

13. The consumable group as claimed in claim 12, wherein, The dispenser defines an upper shoulder, the nozzle defines a lower shoulder, and the locking ring further includes: The upstream end is configured to engage the upper shoulder; and Downstream end, which is configured to engage the lower shoulder.

14. The consumable group as claimed in claim 11, wherein, The electrode is stationary.

15. The consumable group of claim 11, further comprising: A protective cup, configured to mechanically connect the consumable assembly to the operating end of the torch and electrically connect the nozzle to an electrical conductor in the torch.

16. The consumable group of claim 15, further comprising: A shield, wherein the shield and the shield cup together surround the nozzle to protect the nozzle from splashing.

17. A consumable group for a plasma arc torch, comprising: The first sub-box includes: A dispenser that defines a plurality of ports extending from an internal cavity of the dispenser to an external surface of the dispenser; Electrodes, which are disposed within the distributor and are fixedly coupled to the distributor in a non-removable manner; A nozzle defining at least one set of channels that guide gas into a gap defined between the electrode and the nozzle, the nozzle being non-removably and fixedly coupled to the dispenser; and A static arc initiator, the static arc initiator being located in the distributor and positioned to extend into the gap between the electrode and the nozzle; and The second sub-box includes: A shield, configured to cover the distal end of the nozzle; and A shield cup is non-removably and fixedly coupled to the shield, wherein the shield and the shield cup define a seat cavity configured to receive the first sub-box, and the shield cup includes a connector capable of connecting the second sub-box, together with the first sub-box located in the second sub-box, to the operating end of the torch.

18. The consumable group as claimed in claim 17, wherein, The shield cup includes: A first connector, the first connector being used to electrically connect the shield to one or more electrical conductors in the torch; and A second connector is used to electrically connect the nozzle to one or more electrical conductors in the torch.

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