Consumables for processing torches

Abstract

Different sets of consumables that can be used with a shield assembly. Each set of consumables includes a nozzle or tip that has an outer surface that forms an annular gap with the shield assembly when the nozzle is inserted into the shield assembly. The dimensions of the annular gap vary with different nozzles.

Description

Attorney Docket No. 1485.1086i2PATENTCONSUMABLES FOR PROCESSING TORCHES CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 761,720, entitled “Consumables for Processing Torches,” filed February 21, 2025, and claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 829,067, entitled “Consumables for Processing Torches,” filed June 24, 2025, and the entire disclosures of both of the above-identified patent applications are hereby incorporated by reference in their entireties for all purposes.TECHNICAL FIELD

[0002] The present disclosure is directed toward components for welding and cutting torches and, in particular, to consumable components for welding and / or cutting torches.BACKGROUND

[0003] Many welding and cutting torches, such as plasma cutting torches, can receive a variety of consumable components, such as tips / nozzles, electrodes, shields, etc. Generally, consumables, such as electrodes, tips / nozzles, shields, etc., have a limited lifespan and only last for a certain amount of cuts or welds before a user must replace them. Thus, consumables with longer lifespans may save time for a user since a user can continue cutting or welding operations without changing consumables. Additionally, consumables with longer lifespans may provide cost savings for users since a user will not need to purchase replacement consumables as frequently. Thus, consumables with improved lifespans are continuously desired.SUMMARY

[0004] Different sets of consumables that can be used with a shield assembly. Each set of consumables includes a nozzle or tip that has an outer surface that forms an annular gap with the shield assembly when the nozzle is inserted into the shield assembly. The dimensions of the annular gap vary with different nozzles.

[0005] According to one example embodiment, a set of consumables positionable in a shield cup assembly of a plasma arc torch that receives a flow of fluid from a fluid source comprises a nozzle having a cavity; an electrode; and a gas distributor having an opening therethrough, wherein theAttorney Docket No. 1485.1086i2PATENTelectrode is inserted into the opening of the gas distributor, the gas distributor is inserted into the cavity of the nozzle, fluid flows from the gas distributor along an outer surface of the electrode , the nozzle physically engages the gas distributor to couple the nozzle and the gas distributor, and the electrode physically engages the gas distributor to couple the electrode and the gas distributor, wherein the nozzle, the gas distributor, and the electrode are retained together as a unit.

[0006] In one embodiment, the gas distributor has a plurality of passageways, each of which is oriented at an angle from 25 degrees to 45 degrees relative to a longitudinal axis of the electrode.

[0007] In another embodiment, the plurality of passageways are oriented at an angle of 30 degrees relative to the longitudinal axis of the electrode.

[0008] In yet another embodiment, the electrode has an outer surface that includes a conical surface with a proximal end and a distal end, and the fluid flowing from the gas distributor is directed toward and engages the distal end of the conical surface of the electrode.

[0009] In an alternative embodiment, the conical surface is oriented so that its distal end has a larger diameter than its proximal end.

[0010] In one embodiment, the nozzle has a shoulder that has an outer surface, and when the nozzle is placed in the shield cup assembly, an annular gap is formed between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly.

[0011] In an alternative embodiment, a flow of fluid flows into the electrode and is separated into a first flow portion and a second flow portion, the first flow portion travels between the nozzle and the electrode and forms a plasma gas flow, the second flow portion travels between the nozzle and the shield cup assembly and forms a shield gas flow, and the second flow portion flows through the annular gap.

[0012] In another embodiment, a rate of the first flow portion can be adjusted by modifying a configuration of an outlet bore in the nozzle, and a rate of the second flow portion can be adjusted by modifying a width of the annular gap between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly.Attorney Docket No. 1485.1086i2PATENT

[0013] In yet another embodiment, the nozzle has an outer surface with a knurled pattern of grooves formed therein, and the knurled pattern of grooves provide a gripping surface and an improved cooling function for the outer surface of the nozzle.

[0014] According to another example embodiment, a set of consumables positionable in a shield cup assembly of a plasma arc torch that receives a flow of fluid from a fluid source comprises a nozzle having a cavity; an electrode, the electrode having an outer surface that includes a conical surface with a proximal end and a distal end; and a gas distributor having an opening and a plurality of passageways, the electrode being inserted into the opening of the gas distributor, and the gas distributor being inserted into the cavity of the nozzle, wherein fluid flows from the gas distributor along the outer surface of the electrode in a direction that is directed toward and engages the distal end of the conical surface.

[0015] In an alternative embodiment, the nozzle physically engages the gas distributor to couple the nozzle and the gas distributor, and the electrode physically engages the gas distributor to couple the electrode and the gas distributor, wherein the nozzle, the gas distributor, and the electrode are retained together as a unit.

[0016] In one embodiment, the nozzle has a shoulder that has an outer surface, and when the nozzle is placed in the shield cup assembly, an annular gap is formed between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly, and wherein a flow of fluid flows into the electrode and splits into a plasma gas flow and into a shield gas flow, and the shield gas flow travels through the annular gap.

[0017] In another embodiment, the nozzle has an orifice in fluid communication with the cavity of the nozzle, the orifice having an inner diameter, and the inner diameter is in a range of approximately 0.031 inches to approximately 0.060 inches.

[0018] In yet another embodiment, the outer surface of the shoulder of the nozzle defines an outer diameter, and the outer diameter is in a range of approximately 0.713 inches to approximately 0.720 inches.

[0019] In one embodiment, a distance between the outer surface of the shoulder of the nozzle and the inner wall of the shield cup assembly is in a range of approximately 0.004 inches to approximately 0.011 inches.Attorney Docket No. 1485.1086i2PATENT

[0020] In another embodiment, the electrode is engageable with and remains in contact with a contact band in a torch head when the electrode is moved into the torch head.

[0021] According to another example embodiment, a plasma arc torch that receives a flow of fluid from a fluid source, the flow of fluid being split into a first flow portion that is a plasma flow and a second flow portion that is a shield flow comprises a shield assembly including a shield cup member having including a plurality of passageways formed therein, the shield cup member having an inner surface; a first set of consumables engageable with a torch head, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, the first nozzle having a first outlet bore with a first configuration, the first nozzle having a first outer shoulder, the first outer shoulder and the inner surface of the shield cup member defining a first annular gap; and a second set of consumables engageable with the torch head, the second set of consumables including a second nozzle, a second electrode, and a second gas distributor, the second nozzle having a second outlet bore with a second configuration, the second configuration being different from the first configuration, the second nozzle having a second outer shoulder, the second outer shoulder and the inner surface of the shield cup member defining a second annular gap, the second annular gap having a different width than the first annular gap, wherein, depending on which of the first set of consumables or the second set of consumables is engaged with the torch head, the first flow portion travels through either the first outlet bore or the second outlet bore, the second flow portion travels through either the first annular gap or the second annular gap, and the first flow portion and the second flow portion can be adjusted by the first outlet bore and the first annular gap or the second outlet bore and the second annular gap.

[0022] In one embodiment, a width of the first annular gap is either in a range of approximately 0.047 inches to approximately 0.051 inches or in a range of approximately 0.004 inches to approximately 0.011 inches.

[0023] In an alternative embodiment, the first outer shoulder of the first nozzle defines an outer diameter, and the outer diameter is either in a range of approximately 0.673 inches to approximately 0.677 inches or in a range of approximately 0.713 inches to approximately 0.720 inches.Attorney Docket No. 1485.1086i2PATENT

[0024] In another embodiment, the first electrode has an outer surface that includes a conical surface with a proximal end and a distal end, and fluid flowing from the first gas distributor is directed toward and engages the distal end of the conical surface of the first electrode.

[0025] Other systems, methods, features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features and advantages are included within this description, are within the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The consumables for a plasma arc torch presented herein may be better understood with reference to the following drawings and description. It should be understood that the elements in the figures are not necessarily to scale and that emphasis has been placed upon illustrating the principles of the consumables. In the figures, like-referenced numerals designate corresponding parts throughout the different views.

[0027] FIG. 1 A illustrates a perspective view of a manual cutting system including a power source and torch assembly with which the consumables presented herein may be utilized, according to an example embodiment of the present disclosure.

[0028] FIG. IB illustrates a perspective of the torch assembly illustrated in FIG. 1A.

[0029] FIG. 1C illustrates a perspective view of an automated cutting head with which the consumables presented herein may be utilized, according to an example embodiment of the present disclosure.

[0030] FIG. 2 illustrates a perspective view of a consumable cartridge formed from example embodiments of the consumables presented herein.

[0031] FIG. 3 illustrates an exploded perspective view of the consumable cartridge illustrated in FIG. 2.

[0032] FIG. 4 illustrates a cross-sectional side view of the consumable cartridge illustrated in FIG.2.Attorney Docket No. 1485.1086i2PATENT

[0033] FIG. 4A illustrates a side view of the distributor and the electrode of the consumable cartridge illustrated in FIG. 2 with the nozzle removed.

[0034] FIG. 4B illustrates a bottom perspective view of the distributor and the electrode illustrated in the FIG. 4A.

[0035] FIG. 4C illustrates a top perspective view of an alternative embodiment of a consumable cartridge, according to the present disclosure.

[0036] FIG. 4D illustrates a top view of the consumable cartridge illustrated in FIG. 4C.

[0037] FIG. 5 illustrates a top perspective view of an electrode, according to an example embodiment.

[0038] FIG. 6 illustrates a bottom perspective view of the electrode illustrated in FIG. 5.

[0039] FIG. 7 illustrates a side view of the electrode illustrated in FIG. 5.

[0040] FIG. 8 illustrates a cross-sectional side view of the electrode illustrated in FIG. 5.

[0041] FIG. 9 illustrates a top perspective view of a distributor, according to an example embodiment.

[0042] FIG. 10 illustrates a bottom perspective view of the distributor illustrated in FIG. 9.

[0043] FIG. 11 illustrates a side view of the distributor illustrated in FIG. 9.

[0044] FIG. 12 illustrates a cross-sectional side view of the distributor illustrated in FIG. 9.

[0045] FIG. 13 illustrates a top perspective view of a nozzle, according to an example embodiment.

[0046] FIG. 14 illustrates a bottom perspective view of the nozzle illustrated in FIG. 13.

[0047] FIG. 15 illustrates a side view of the nozzle illustrated in FIG. 13.

[0048] FIG. 16 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 13.

[0049] FIG. 17A illustrates a cross-sectional side view of another embodiment of a nozzle, according to the present disclosure.

[0050] FIG. 17B illustrates a cross-sectional side view of another embodiment of a nozzle, according to the present disclosure.Attorney Docket No. 1485.1086i2PATENT

[0051] FIG. 17C illustrates a cross-sectional side view of another embodiment of a nozzle, according to the present disclosure.

[0052] FIG. 17D illustrates a cross-sectional side view of another embodiment of a nozzle, according to the present disclosure.

[0053] FIG. 18A illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0054] FIG. 18B illustrates a cross-sectional side view of the nozzle illustrated in FIG. 18A.

[0055] FIG. 19 illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0056] FIG. 20 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 19.

[0057] FIG. 21 illustrates a cross-sectional side view of another embodiment of a nozzle, according to the present disclosure.

[0058] FIG. 21A illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0059] FIG. 21B illustrates an exploded side view of the nozzle illustrated in FIG. 21A.

[0060] FIG. 21C illustrates a cross-sectional exploded side view of the nozzle illustrated in FIG.21A.

[0061] FIG. 2 ID illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0062] FIG. 2 IE illustrates a cross-sectional side view of the nozzle illustrated in FIG. 2 ID.

[0063] FIG. 22 illustrates a top perspective view of a shield, according to an example embodiment.

[0064] FIG. 23 illustrates a bottom perspective view of the shield illustrated in FIG. 22.

[0065] FIG. 24 illustrates a side view of the shield illustrated in FIG. 22.

[0066] FIG. 25 illustrates a cross-sectional view of the shield illustrated in FIG. 22.

[0067] FIG. 26 illustrates a top perspective view of torch head components and a consumable cartridge, according to an example embodiment.Attorney Docket No. 1485.1086i2PATENT

[0068] FIG. 27 illustrates an exploded side view of several of the torch head components illustrated in FIG. 26.

[0069] FIG. 28 illustrates a top perspective view of several torch head components in an assembled configuration.

[0070] FIG. 29 illustrates a bottom perspective view of the torch head components illustrated in FIG. 28.

[0071] FIG. 30 illustrates a perspective view of an embodiment of a contact spring.

[0072] FIG. 31 illustrates another perspective view of the contact spring illustrated in FIG. 30.

[0073] FIG. 32 illustrates an exploded perspective view of the torch head components illustrated in FIG. 28.

[0074] FIG. 33 illustrates a top perspective view of a screw used in the torch head components illustrated in FIG. 32.

[0075] FIG. 34 illustrates a cross-sectional side view of the torch head components illustrated in FIG. 32.

[0076] FIG. 35 illustrates a side view of one of the torch head components illustrated in FIG. 32.

[0077] FIG. 36 illustrates a top view of the torch head component illustrated in FIG. 35.

[0078] FIG. 37 illustrates a bottom view of the torch head component illustrated in FIG. 35.

[0079] FIG. 38 illustrates a cross-sectional side view of the torch head component illustrated in FIG. 35.

[0080] FIG. 39 illustrates a top perspective view of another one of the torch head components illustrated in FIG. 32.

[0081] FIG. 40 illustrates a bottom perspective view of the torch head component illustrated in FIG. 39.

[0082] FIG. 41 illustrates a cross-sectional side view of the torch head component illustrated in FIG. 39.Attorney Docket No. 1485.1086i2PATENT

[0083] FIG. 42 illustrates a side view of another one of the torch head components illustrated in FIG. 32.

[0084] FIG. 43 illustrates a top perspective view of the torch head component illustrated in FIG.42.

[0085] FIG. 44 illustrates a bottom perspective view of the torch head component illustrated in FIG. 42.

[0086] FIG. 45 illustrates a cross-sectional perspective view of the torch head component illustrated in FIG. 42.

[0087] FIG. 46 illustrates a side view of a shield cup assembly and an insulator in an assembled configuration, according to an example embodiment.

[0088] FIG. 47 illustrates an exploded perspective view of the shield cup assembly and the insulator illustrated in FIG. 46.

[0089] FIG. 48 illustrates an exploded cross-sectional side view of the shield cup assembly and insulator illustrated in FIG. 47.

[0090] FIG. 49 illustrates an assembled cross-sectional side view of the shield cup assembly and insulator illustrated in FIG. 47.

[0091] FIG. 50 illustrates a top perspective view of a proximal shield cup member of the shield cup assembly illustrated in FIG. 46.

[0092] FIG. 51 illustrates a top view of the proximal shield cup member illustrated in FIG. 50.

[0093] FIG. 52 illustrates a top perspective view of the distal shield cup member illustrated in FIG.50.

[0094] FIG. 53 illustrates a perspective view of a spring or cage, according to an embodiment of the present disclosure.

[0095] FIG. 54 illustrates a top perspective view of an electrode holder and an O-ring, according to an embodiment of the present disclosure.

[0096] FIG. 55 illustrates a cross-sectional side view of the electrode holder, the O-ring, and the cage illustrated in FIGS. 53 and 54.Attorney Docket No. 1485.1086i2PATENT

[0097] FIG. 55 A illustrates a cross-sectional side view of some torch components with an electrode in a first position.

[0098] FIG. 55B illustrates a cross-sectional side view of the torch components of FIG. 55A with the electrode in a second position.

[0099] FIG. 56 illustrates a perspective view of an embodiment of a sensor probe, according to the present disclosure.

[0100] FIG. 57 illustrates a cross-sectional side view of the torch head assembly and the consumable cartridge illustrated in FIG. 26.

[0101] FIG. 58 illustrates a slightly different cross-sectional side view of the torch head assembly and the consumable cartridge illustrated in FIG. 57.

[0102] FIG. 59 illustrates a cross-sectional side view of a consumable cartridge for a 110 Amp torch.

[0103] FIG. 60 illustrates a cross-sectional side view of a consumable cartridge for a 30 Amp torch.

[0104] FIG. 61 illustrates a close-up cross-sectional side view of a torch head assembly including a consumable cartridge for a 110 Amp torch.

[0105] FIG. 62 is another close-up cross-sectional side view of the torch head assembly in FIG. 61.

[0106] FIGS. 63-65 are different side views showing the air flow exiting the gas distributor proximate to the electrode surface.

[0107] FIG. 66 is a close-up side view of a portion of a disposable consumable module (DCM) according to the present invention.

[0108] FIGS. 67 and 68 are cross-sectional side views of a DCM according to the present invention.

[0109] FIG. 69 is a proximal end view of an embodiment of a DCM according to the present invention.Attorney Docket No. 1485.1086i2PATENT

[0110] Like reference numerals have been used to identify like elements throughout this disclosure.DETAILED DESCRIPTION

[0111] Consumables for cutting and / or welding torches are presented herein. To control fluid and or gas flow through a plasma cutting torch, drop in consumable cartridges with different dimensions are used. Specifically, to control plasma gas flow by using a drop in consumable cartridge that acts similar to a needle valve to control fluid flow. Each different consumable cartridge is specifically designed for a particular amperage level, and thus, will have a different physical feature that performs the act of controlling fluid flow. The consumable cartridge, in combination with a shield cup assembly, will allow either more or less fluid flow based on what the amperage requires for optimal flow through the plasma orifice and total flow through the torch.

[0112] The disclosed techniques relate to controlling fluid flow with only the drop in consumable cartridge. In a torch that is universally designed, any level of consumable cartridge based on its amperage level could be dropped into or coupled to the torch, thereby resulting in the correct flow for both the plasma orifice and the total flow through the torch. Without changing any portion of the torch design, or blocking or shutting off any holes, the disclosed techniques add a level of resistance to control the amount of fluid through the components of the torch by finding the specific geometry required to achieve the desired fluid flows.

[0113] In one implementation, the torch can be used with consumable cartridges that will be useable with amperages from between 130 Amp to 30 Amp at every 20Amp increments. In another implementation, the torch can be used with consumable cartridges that are useable with variety of amperages for cutting processes, including 30 Amp, 40 Amp, 50 Amp, 70 Amp, 90 Amp, 110 Amp, and fine cutting processes, as well as different amperages for gouging processes, including 70 Amp and 90 Amp processes. As the torch is universal, the only thing changing for the different cutting processes and gouging processes is the consumable cartridge that is dropped or inserted into the torch. Each consumable cartridge has a plasma hole orifice that remains the same to achieve consistent cut quality, size, and speed. This orifice is one way that gas is being passed through the torch and the cartridge. Another way the gas is being passed through the torch is by a shield cup insulator that has slots cut into it in the shield cup. The shield cup holds andAttorney Docket No. 1485.1086i2PATENTcovers the consumable cartridge. The shield cup insulator holes do not change from amperage to amperage because this is part of the universal torch. Therefore, the stream of gas is controlled through the shield cup insulator slots or passages without actually changing the shield cup insulator. One way of controlling the fluid flow is similar to a needle valve. A specific sized diameter shoulder is added to the nozzle of the consumable cartridge that restricts air flow from the shield cup insulator. The restriction functions as a flow restriction or choking feature, which forces more air through the plasma orifice and less through the shield region, which collectively is the total flow.

[0114] When a plasma arc initiates or terminates in an existing steady and distinct air flow and pressure environment, it causes a dramatic flow restriction and pressure drop for a few seconds. After that brief period, the plasma arc has mostly stabilized to reduced output values, depending on where flow and pressure are being measured. Generally, it is desirous for a torch to behave in a steady state condition. In some applications, it is more difficult to cut at a constant speed when a plasma arc, air pressure, and air flow are in a state of change. In addition, being in a transient state for a plasma arc is when there is an increased loss of hafnium from the electrode.

[0115] In another aspect of the disclosed techniques, a shield cup assembly design that covers a large electrical current range in plasma cutting applications includes a retaining cup, a front shield cap, a gas distribution ring and an electrical insulator, which collectively form a shield cup assembly. By using a single shield cup assembly, all DCMs for different amperages can be installed and retained at a designated position for both electrical contact and shield gas flow metering. Using a universal shield cup assembly provides a benefit for customers for easy installation and for reduced handling / operational errors during cutting operations at different amperages.

[0116] In one implementation, DCMs for different amperages have different total lengths due to the sizes of the nozzles. In one implementation, the shield cup assembly works for all amperages from 30 Amp to 130 Amp DCMs. In a plasma cutting operation, the desired DCM is inserted into the torch head, and then the shield cup is secured. As the shield cup assembly is threaded up with regular hand torque, the DCM is centered with the cup and the top of the electrode is engaged with the electrical contact band located in the center of torch body. The keying features (such as notch 424 described below) are not long enough to engage before the shield cup is startedAttorney Docket No. 1485.1086i2PATENTto be threaded onto the torch. In addition, there is currently not enough friction inside the shield cup to rotate the DCM and make it “find” its mate, especially after the rear of the electrode has engaged the spring or cage in the electrode holder.

[0117] In one implementation, the following parameters are unchanged for all amperages: the internal distance of the nozzle to the shield cap front (SI), the wall gap between the nozzle and the shield cap (S2), and the shield cap orifice diameter (W). To balance or meter the gas flows of plasma and shield gas, the gap between the nozzle outer diameter and the inner diameter of the shield retaining cup (G) is adjusted based on the nozzle orifice diameter (D) with a relationship of: G = (0.5 ~ 0.75) x D. The shield gas metering gap (G) is adjusted by changing the nozzle outer diameter in a DCM. In one example, for a 130 Amp DCM, D =0.069” and G =0.050”. To achieve good cutting quality, the cold plasma flow rate is kept at the range of 150 -190 SCFH and the total cold flow rate through shield cap orifice is 500 -600 SCFH.

[0118] In different implementations, the front shield cap can be attached to the retaining cup with thread jointing or crimping or welding. Also, the shield cup assembly can be modified for plasma gouging and drag cutting applications.

[0119] In one implementation, a microswitch or a switch probe is used to perform a consumable Part in Place (PIP) function. A camera embedded inside of a plasma torch can be used to perform the function of identifying parts of a DCM amperage and / or cutting applications such as standard cutting or gouging. In an alternative implementation, a device that includes a microswitch (or switch probe) and a miniaturized displacement sensor or a potentiometric distance measurement are combined to identify the cutting amperages and different applications such as plasma gouging. This device is embedded inside torch body as well.

[0120] FIG. 1 A illustrates an example embodiment of a manual cutting system 10 that may utilize the consumable components presented herein. At a high-level, the manual cutting system 10 includes a power supply 12 and a torch assembly 40. The power supply 12 is configured to supply (or at least control the supply of) power and gas to a torch 50 included in the torch assembly 40 via torch lead 42 (also referred to as cable hose 42). For example, the power supply 12 may meter a flow of gas received from a gas supply 20, which the power supply 12 receives via cable hose 22, before or as the power supply 12 supplies gas to the torch 50 via cable hose 42.Attorney Docket No. 1485.1086i2PATENT

[0121] The manual cutting system 10 also includes a working lead assembly 30 with a grounding clamp 32 that is connected to the power supply by a work lead 34 (also referred to as cable hose 34). As illustrated, cable hose 22, cable hose 34, and cable hose 42 may each be any length. Moreover, each end of cable hose 22, cable hose 34, and cable hose 42 may be connected to components of the manual cutting system 10 via any connectors now known or developed hereafter (e.g., via releasable connectors). For example, torch 50 may be connected to a distal end of cable hose 42 via a quick disconnect connector 46 and power supply 12 may be connected to a proximal end of cable hose 42 via a quick disconnect connector 44.

[0122] FIG. IB illustrates the torch assembly 40 of FIG. 1 A independently from the power supply 12. As can be seen, the torch 50 includes a torch body 52 that extends from a first end 56 (e g., a connection end 56) to a second end 54 (e.g., an operating or operative end 54). The torch body 52 may also include a trigger 58 that allows a user to initiate cutting operations in any manner now known or developed hereafter (e.g., in a 2T or 4T mode). As mentioned above, the connection end 56 of the torch body 52 may be coupled (in any manner now known or developed hereafter) to one end of lead 42 Meanwhile, the operative end 54 of the torch body 52 may receive interchangeable components, such as consumable components that facilitate cutting operations. The consumable stack presented herein, which is depicted installed on torch 50 in FIG. IB, is generally referred to as consumable stack 70 in FIG. IB; however, the depiction shown in FIG. IB is merely representative of a consumable stack that includes the features presented herein.

[0123] FIG. 1C illustrates an example embodiment of an automated cutting head 60 that may utilize the consumable components presented herein. As can be seen, the cutting head 60 includes a body 62 that extends from a first end 63 (e.g., a connection end 63) to a second end 64 (e.g., an operating or operative end 64). The connection end 63 of the body 62 may be coupled (in any manner now known or developed hereafter) to an automation support structure (e.g., a cutting table, robot, gantry, etc.) and conduits 65 extending therefrom may be coupled to like conduits in the automation support structure to connect the automated cutting head 60 to a power supply, a gas supply, a coolant supply, and / or any other components supporting automated cutting operations. Meanwhile, the operative end 64 of the body 62 may receive interchangeable components, including consumable components that facilitate cutting operations. Again, theAttorney Docket No. 1485.1086i2PATENTconsumable stack 70 depicted in FIG. 1C is merely representative of a consumable stack that includes the features presented herein (like the stack 70 depicted in FIG. IB).

[0124] For simplicity, FIGS. 1A, IB, and 1C do not illustrate an interior of torch body 52 or body 62. However, it is to be understood that any unillustrated components that are typically included in a torch, such as components that facilitate welding or cutting operations, may (and, in fact, should) be included in a torch configured in accordance with an example embodiment of the present invention. Additionally, none of FIGS. 1A, IB, and 1C, or any other figures, illustrates connections portions of the bodies 52 / 62 in detail; however, it should be understood that the consumables presented herein may be coupled to a torch body 52 / 62 that includes features configured to mate with features of the consumables, examples of which are described in detail below.

[0125] Now turning to FIGS. 2-4, an example embodiment of a consumable cartridge is illustrated. In this embodiment, the consumable cartridge 100 has a proximal end 102 and a distal end 104 opposite the proximal end 102. The proximal end 102 is the end of the consumable cartridge 100 that is connected to a torch head assembly. Referring to FIG. 2, the consumable cartridge 100 has a fluid entry way 106 into which gas flows. The gas flowing into the fluid entryway 106 is later split into a plasma gas flow and a shield gas flow, as described in detail below.

[0126] In FIGS. 2 and 3, the various components of the consumable cartridge 100 are illustrated in assembled and exploded perspective views, respectively. In particular, in this embodiment, the consumable cartridge 100 includes an electrode 200, a gas distributor or insulator 300, a tip or nozzle 400, and an arc initiator 500, such as a pin. The nozzle 400 is sized to receive both a portion of the gas distributor 300 and a portion of the electrode 200. In addition, the gas distributor 300 is sized to receive a portion of the electrode 200. The arc initiator 500 is inserted into an opening of the gas distributor 300 and extends therethrough. A distal end of the arc initiator 500 is located so that it extends into a plasma gas flow in the consumable cartridge 100.

[0127] In FIG. 2, the nozzle 400 has an outer surface 414 that includes a grooved or knurled pattern of grooves 470 formed therein. In this embodiment, the consumable cartridge 100 includes two O-rings 270 and 272 (see FIG. 3) that are located in grooves formed in the outer surface of theAttorney Docket No. 1485.1086i2PATENTgas distributor 300. The relative locations of the O-rings 270 and 272 along the gas distributor 300 are described in greater detail below. The knurled pattern of grooves 470 provide a gripping surface for a user to grasp and manipulate the nozzle. In addition, the knurled grooves 470 provide an increased surface area pattern that improves the cooling of the outer surface of the nozzle.

[0128] Referring to FIG. 4, a cross-sectional side view of the consumable cartridge 100 is illustrated. The fluid or gas flow from a pressurized fluid or gas source (not shown) enters the fluid entryway 106. The fluid or gas flow 1500 entering the fluid entryway 106 travels through channel 216 and exits openings 222 in the electrode 200. As described in greater detail below, the gas flow 1500 is split into two separate flows, which are a plasma gas flow and a shield gas flow. The plasma gas flow portions 1510 and 1520 are illustrated by the arrows in FIG. 4, which represent the plasma gas flow after it has been split. The plasma gas flow portions 1510 and 1520 flow through the gas distributor 300 and exits openings 324 in the gas distributor 300. The plasma gas flow portions 1510 and 1520 then flow inside of the nozzle 400 to a plasma chamber 108 and then out of nozzle 400 through bore 434. At the distal end of the electrode a bore 234 is formed therein. The bore 234 is sized to receive an emissive insert 280 therein, as shown in FIG. 4. In different embodiments, the length and width of both the bore 234 and the emissive insert 280 can vary. In FIG. 4, the O-rings 270 and 272 are illustrated in their positions on the outside of the gas distributor 300. O-ring 272 is located between the outer surface of the gas distributor 300 and the inner surface of the nozzle 400.

[0129] Turning to FIGS. 4A and 4B, different views of several components of consumable cartridge 100 are illustrated in their assembled positions. As shown, the arc initiator 500 extends through the gas distributor 300. O-ring 272 is located in one of the external grooves of the gas distributor 300. The electrode 200 extends through gas distributor 300 as well.

[0130] Referring to FIGS. 4C and 4D, a top perspective view and a top view of an alternative embodiment of a consumable cartridge according to the present disclosure are illustrated. In this embodiment, the electrode 200’ is exemplary of an electrode that can be used with a nozzle 400’ . In this embodiment, nozzle 400’ has a radial flange 420’ at its distal end. The radial flange 420’ can have indicia 421’ on its upper surface that is readable by a sensor, such as a camera. The indicia 421’ can identify the source of the nozzle 400’ and the consumable cartridgeAttorney Docket No. 1485.1086i2PATENTas well as the characteristics and intended use of the nozzle 400’ (such as which amperage(s) operations). The nozzle 400’ also includes a notch 424’ that is used for a keying function.

[0131] Turning to FIGS. 5-8, various views of an example embodiment of an electrode are illustrated. The electrode 200 includes a proximal end 210 and a proximal portion 212 adjacent to the proximal end 210 The proximal end 210 has an opening 213 formed therein, that is the fluid entryway 106 discussed relative to FIG. 2. The proximal portion 212 includes a wall that has an inner wall surface 214 that defines a channel 216 that extends inside of the electrode 200. The opening 213 is at the entrance to the channel 216, and is sized to receive the gas flow 1500. The electrode includes several openings 222 that are formed through the wall to fluidically couple the channel 216 with the outside of the electrode 200.

[0132] The electrode 200 includes a distal end 230 and a distal portion 232 adjacent to the distal end 230. Both the distal end 230 and the distal portion 232 are located inside of the nozzle 400, as described below. As shown in FIG. 6, the distal end 230 has a bore 234 in which an emissive insert (not shown in FIG. 6) is placed. The bore 234, and thus, the emissive insert, are located at the plasma chamber 108.

[0133] Turning to FIGS. 7 and 8, a side perspective view and a side cross-sectional view of the electrode are illustrated, respectively. As shown, the electrode 200 includes a middle portion 236 that has an outer surface 202 and an outer diameter that is larger than the outer diameter of the proximal portion 212. The outer surface 202 includes several spaced apart grooves 204 formed therein, each of which extends around the perimeter of the outer surface 202. Adjacent to each groove 204 is a rib or ridge 206 that is formed by adjacent grooves 204. The alternating grooves 204 and ribs 206 provide a cooling function for the electrode 200 that is achieved by air flowing along outer surface 202.

[0134] The electrode 200 includes a shoulder 240 that is located distal to the middle portion 236. The shoulder 240 has several different surfaces that collectively form a contoured outer surface. In particular, the shoulder 240 includes a step 242 that leads to a cylindrical outer surface 246 that defines a portion with an outer diameter that is larger than the outer diameter of the middle portion 236. As shown in FIG. 8, step 242 includes a recess formed in its distal surface that forms a groove 244.Attorney Docket No. 1485.1086i2PATENT

[0135] The shoulder 240 includes another step 248, which defines an outer diameter that is larger than the outer diameter of surface 246. Step 248 leads to an angled surface 250 that is tapered or angled outwardly toward a ridge 252. The angled surface 250 is tapered outwardly as it is closer to the distal end 230 of the electrode 200. The ridge 252 defines the largest outer diameter of the electrode 200. In other words, the outer diameter of the ridge 252 is larger than the outer diameter of step 248. On the distal side of ridge 252 is another angled or tapered surface 254 that is angled inwardly as it approaches in the direction of the distal end 230. Adjacent to angled surface 254 is another angled surface 256 that has a slightly different angle than angled surface 254. As shown in FIG. 7, angled surface 256 leads to distal portion 232. As shown in FIG. 8, the distal end 230 includes a bore 234 formed therein, as described above. An emissive insert (not shown) can be disposed in the bore 234.

[0136] Also shown in the cross-sectional view of FIG. 8 are the features of the proximal portion 212 of the electrode 200. The inner wall surface 214 that defines the channel 216 is shown. The channel 216 has a proximal end 218, which is at the opening 213 formed in the proximal end 210. The channel 216 has a distal end 220 that is opposite to its proximal end 218. In this embodiment, the channel 216 extends through the length of the proximal portion 212. Slightly upstream toward the proximal end 218 from the distal end 220 are several openings 222, which were discussed above. In one implementation, four openings 222 are formed through the wall of the electrode 200, the centers of each of which is located 90 degrees away from a center of an adjacent opening 222 around the perimeter of the electrode 200. The openings 222 permit the flow of gas therethrough. In alternative implementations, the quantity of openings formed through the wall of the electrode can vary. For example, in different embodiments, the quantity can be three or six or a different amount.

[0137] Turning to FIGS. 9-12, several different views of an example embodiment of a gas distributor or insulator are illustrated. Initially referring to FIGS. 9-11, the gas distributor 300 has an upstream or proximal end 310 and a downstream or distal end 320. The gas distributor 300 has an upstream section 312 that is adjacent to the proximal end 310, and a downstream section 322 that is adjacent to the distal end 320. The gas distributor 300 has an outer surface 330 that has several notches 332 formed therein. In this embodiment, the outer surface 330 has three notchesAttorney Docket No. 1485.1086i2PATENT332 formed therein. In addition, the outer surface 330 of the gas distributor 300 has a pair of grooves 334 and 336 formed therein that extend around the perimeter of the outer surface 330.

[0138] Referring to FIG. 9, the gas distributor 300 has an inwardly oriented radial flange 340 with an inner wall surface 342. Formed in the flange 340 is a through hole 370 into which an arc initiator 500 can be inserted. In this embodiment, the through hole 370 extends parallel to a longitudinal axis of the gas distributor 300. The through hole 370 extends from the proximal end 310 of the gas distributor 300 (see FIG. 10) to the distal end 320 of the gas distributor 300 (see FIG. 11). In FIG. 10, the gas distributor 300 also has an inner wall surface 354 that defines a pass through channel or passageway 380 that extends through the body of the gas distributor 300.

[0139] Referring back to FIG. 9, the gas distributor 300 has several openings 360 formed in an inner wall surface. Referring to FIG. 11, the distal end 320 of the gas distributor 300 has several openings 324 formed therein. In this implementation, the quantity of openings 360 and the quantity of openings 324 are the same.

[0140] Turning to the cross-sectional view in FIG. 12, the various features of the gas distributor 300 are illustrated. The through hole 370 for the arc initiator 500 is shown extending from the proximal end 310 to the distal end 320. In addition, passageways 362 between openings 360 inside the gas distributor 300 and openings 324 in the distal end 320 are shown. Gas flow entering openings 360 after it has exited the electrode 200 travels through the passageways 362 and exits openings 324 on its way to the plasma chamber 108. In one embodiment, the passageways 362 and the related corresponding openings 360 and 324 are oriented to swirl air in a direction of approximately 30 degrees relative to a longitudinal axis of the gas distributor 300. The airflows exiting openings 324 are directed into the plasma chamber in a swirling pattern.

[0141] Inside the gas distributor 300 are the inner wall surface 342 of the radial flange 340 and an inner wall surface 350 below the radial flange 340. The inner diameter defined by inner wall surface 350 is larger than the inner diameter defined by inner wall surface 342, which results in a groove 353 formed around the inner perimeter of the gas distributor 300. Air is permitted to flow in the groove 353 and enter the openings 360. At the end of inner wall surface 350 is a ledge 352 that extends inwardly to inner wall surface 354 that has a smaller inner diameter than inner wall surface 342 as shown in FIG. 12. The openings 360 are formed in both the inner wall surfaceAttorney Docket No. 1485.1086i2PATENT350 and the ledge 352. Each of the openings 360 is formed at an angle relative to a longitudinal axis of the gas distributor 300 so that the passageways 362 have radial curved orientations around the inside of the gas distributor 300.

[0142] In FIG. 12, the outwardly oriented grooves 334 and 336 that are formed in the outer surface 330 of the gas distributor 300 are shown. Groove 334 is closer to upstream end 310 than groove 336 is, and likewise, groove 336 is closer to downstream end 320 than groove 334 is. In other words, the distance between groove 334 and upstream end 310 is less than the distance between groove 336 and upstream end 310. Similarly, the distance between groove 336 and downstream end 320 is less than the distance between groove 334 and downstream end 320.

[0143] Turning to FIGS. 13-16, an example embodiment of a nozzle or tip is illustrated in several different views. The embodiment of the nozzle 400 illustrated in FIGS. 13-16 is exemplary of a nozzle that can be used in a plasma arc torch for a 30 Amp operation. As illustrated in FIG.15, the nozzle 400 has a proximal end 410 with a proximal portion 412 located adjacent thereto, and has a distal end 430 that is located opposite to proximal end 410 and that has a distal portion 432 located adjacent thereto. The view illustrated in FIG. 13 shows the inside of the nozzle 400. The nozzle 400 has an inner surface 450 that defines an internal cavity 460. The inner surface 450 has a ledge 452 formed therein, which is shown in the cross-sectional side view of FIG. 16.

[0144] As shown in FIGS. 13-16, the proximal portion 412 includes a radial flange 420 that extends outwardly. The radial flange 420 may be referred to alternatively as an upper cylindrical portion. The radial flange 420 has an outer surface 422 in which a notch 424 is formed. The radial flange 420 has a lower surface 426 (see FIG. 16) as well. At the opposite end of the nozzle 400, the distal end 430 has a bore 434 formed therein through which plasma gas flows from the plasma chamber 108.

[0145] The inner and outer profiles of this embodiment of the nozzle 400 are illustrated in FIGS. 15 and 16. As shown, the widest portion of the nozzle 400 is defined by the outer surface 422 of the radial flange 420. Below the radial flange 420, the nozzle 400 has an outer surface 414 that has several different sections with varying outer diameters and configurations, and a convergent section 416 that is angled or tapered toward the distal end 430.Attorney Docket No. 1485.1086i2PATENT

[0146] Referring to FIG. 15, the outer surface 414 of the nozzle 400 has a profile that includes several different surfaces or surface portions. In this embodiment, between the radial flange 420 and the convergent section 416, the outer surface 414 includes an angled surface 426A, a cylindrical surface 426B, an angled surface 426C, and a cylindrical surface 426D. Each of those cylindrical surfaces has a different constant outer diameter, and the alternating angled and cylindrical surfaces collectively transition the outer profile of the nozzle 400 from the radial flange 420 to the distal end 430.

[0147] Turning to FIG. 16, the inner surface 450 defines the cavity 460 of the nozzle 400, which receives a portion of the electrode 200. The inner surface 450 also includes several different sections with varying inner diameters and configurations. As mentioned above, the inner surface 450 has a ledge 452, which is engaged by the distal end 320 of the gas distributor 300 (see FIG.4). As the inner surface 450 progresses from the proximal end 410 toward the distal end 430, each section of the inner surface 450 has a smaller inner diameter than the prior section. The inner surface 450 is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0148] In this embodiment, the bore 434 has an inner tapered bore portion 437, a central bore portion 436 with a cylindrical profile, and an outer bore portion 435 that has an inner diameter that is larger than the inner diameter of the central bore portion 436. The outer bore portion 435 terminates in an orifice 438 at the outer end thereof, which is located in the distal end 430 of the nozzle 400.

[0149] The relative lengths of the portions of bore 434 are shown in FIG. 16 as well. Central bore portion 436 is the longest part of the bore 434 with a length dimension “b”. The outer bore portion 435 has a length dimension “a”, which is slightly greater than the length dimension “c” of inner bore portion 437. It is also noted that the inner diameter of outer bore portion 435 is larger than the inner diameter of the inner bore portion 437, which in turn is larger than the inner diameter of the central bore portion 436.

[0150] FIGS. 17A-21 illustrate various embodiments of nozzles according to the present disclosure. FIG. 17A illustrates an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 40 Amp cutting operation. FIG. 17B illustrates an exemplary embodiment of aAttorney Docket No. 1485.1086i2PATENTnozzle that can be used in a plasma arc torch for a 50 Amp cutting operation. FIG. 17C illustrates an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 70 Amp cutting operation. FIG. 17D illustrates an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 90 Amp cutting operation. FIGS. 18A and 18B illustrate an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 110 Amp cutting operation. FIGS. 19 and 20 illustrate an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 70 Amp gouging operation. FIG. 21 illustrates an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 90 Amp gouging operation.

[0151] In one alternative embodiment, each of the different amperage nozzles has an inner profile that is slightly different dimension-wise relative to the inner profiles of the other nozzles. When the nozzle is inserted into a shield assembly, the outer profile of the inserted nozzle defines an annular gap between the nozzle outer profile and the inner surface of the shield assembly. The annular gap is the space through which a shield gas flow travels. Due to the differences in the outer profiles, the sizes of the annular gaps between the nozzles and the shield assembly will vary. When the size of the annular gap decreases from one nozzle to the other nozzle, the pressure drop for the shield gas flow increases and the flow of the shield gas decreases, which will increase the flow of the plasma gas.

[0152] Initially turning to FIG. 17A, a cross-sectional side view of nozzle 400A is illustrated. The outer surface of the nozzle 400A has a profile with several different surfaces or surface portions, similar to those of nozzle 400. The inside of the nozzle 400A has an inner surface that defines an internal cavity of the nozzle 400A that receives a portion of the electrode, and also includes several different sections with varying inner diameters and configurations. As the inner surface progresses toward the distal end 430A, each of section of the inner surface has a smaller inner diameter than the prior section. The inner surface is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0153] Nozzle 400A includes a distal portion 432A with a distal end 430A and a bore 434A formed in the distal end 430A. In this embodiment, the bore 434A has an inner bore portion 437A that has a tapered profile, a central bore portion 436A with a cylindrical profile, and an outer bore portion 435A with a cylindrical profile. The outer bore portion 435A has an inner diameter “el”Attorney Docket No. 1485.1086i2PATENTthat is larger than an inner diameter of the central bore portion 436A, which is shown as “dl”. The outer bore portion 435 A terminates in an orifice 438 A at the outer end thereof. The relative lengths of each of the portions of bore 434A are shown in FIG. 17A as well. Central bore portion 436A is the longest part of the bore 434A with a length dimension “bl”. The outer bore portion 435A has a length dimension “al”, which is shorter than length dimension “bl” of central bore portion 436A. Similarly, the inner bore portion 437A has a length dimension “cl” that is shorter than both of the length dimensions “al” and “bl”.

[0154] Turning to FIG. 17B, nozzle 400B includes a distal portion 432B with a distal end 430B and a bore 434B formed in the distal end 430B. In this embodiment, the bore 434B has an inner bore portion 437B that has a tapered profile, a central bore portion 436B with a cylindrical profile, and an outer bore portion 435B with a cylindrical profile. The outer bore portion 435B has an inner diameter “e2” that is larger than an inner diameter of the central bore portion 436B, which is shown as “d2”. The outer bore portion 435B terminates in an orifice 438B at the outer end thereof. The relative lengths of each of the portions of bore 434B are shown in FIG. 17B as well. Central bore portion 436B is the longest part of the bore 434B with a length dimension “b2”. The outer bore portion 435B has a length dimension “a2”, which is shorter than length dimension “b2” of central bore portion 436B. Similarly, the inner bore portion 437B has a length dimension “c2” that is shorter than both of the length dimensions “a2” and “b2”. In this embodiment, the dimensions “a2” and “e2” for the outer bore portion 435B of nozzle 400B are larger than dimensions “al” and “el”, respectively, for the outer bore portion 435A of nozzle 400A. In addition, dimension “b2” in nozzle 400B is larger than dimension “bl” in nozzle 400A.

[0155] Turning to FIG. 17C, nozzle 400C includes a distal portion 432C with a distal end 430C and a bore 434C formed in the distal end 430C. In this embodiment, the bore 434C has an inner bore portion 437C that has a tapered profile, a central bore portion 436C with a cylindrical profile, and an outer bore portion 435C with a cylindrical profile. The outer bore portion 435C has an inner diameter “e3” that is larger than an inner diameter of the central bore portion 436C, which is shown as “d3”. The outer bore portion 435C terminates in an orifice 438C at the outer end thereof. The relative lengths of each of the portions of bore 434C are shown in FIG. 17C as well. Central bore portion 436C is the longest part of the bore 434C with a length dimension “b3”. The outer bore portion 435C has a length dimension “a3”, which is shorter than length dimensionAttorney Docket No. 1485.1086i2PATENT“b3” of central bore portion 436C. Similarly, the inner bore portion 437C has a length dimension “c3” that is shorter than both of the length dimensions “a3” and “b3”. In this embodiment, the dimension “e3” for the outer bore portion 435C of nozzle 400C is larger than dimension “e2”, respectively, for the outer bore portion 435B of nozzle 400B. In addition, dimension “b3” in nozzle 400C is larger than dimension “b2” in nozzle 400B.

[0156] Turning to FIG. 17D, nozzle 400D includes a distal portion 432D with a distal end 430D and a bore 434D formed in the distal end 430D. In this embodiment, the bore 434D has an inner bore portion 437D that has a tapered profile, a central bore portion 436D with a cylindrical profile, and an outer bore portion 435D with a cylindrical profile. The outer bore portion 435D has an inner diameter “e4” that is larger than an inner diameter of the central bore portion 436D, which is shown as “d4”. The outer bore portion 435D terminates in an orifice 438D at the outer end thereof. The relative lengths of each of the portions of bore 434D are shown in FIG. 17D as well. Central bore portion 436D is the longest part of the bore 434D with a length dimension “b4”. The outer bore portion 435D has a length dimension “a4”, which is shorter than length dimension “b4” of central bore portion 436D. Similarly, the inner bore portion 437D has a length dimension “c4” that is shorter than both of the length dimensions “a4” and “b4”. In this embodiment, the dimensions “d4” and “e4” for the outer bore portion 435D of nozzle 400D is larger than dimensions “d3” and “e3”, respectively, for the outer bore portion 435C of nozzle 400C. In addition, dimension “a4” in nozzle 400D is larger than dimension “a3” in nozzle 400C.

[0157] Referring to FIGS. 18A and 18B, another embodiment of a nozzle or tip according to the present disclosure is illustrated. The embodiment of the nozzle 400E illustrated in FIGS.18A and 18B is exemplary of a nozzle that can be used in a plasma arc torch for a 110 Amp cutting operation. As illustrated in FIG. 18 A, the nozzle 400E has a proximal end 410E with a proximal portion 412E located adjacent thereto, and has a distal end 430E that is located opposite to proximal end 410E and that has a distal portion 432E located adjacent thereto.

[0158] An outer surface 414E of the nozzle 400E has a profile that includes several different surfaces or surface portions. The outer surface 414E includes a cylindrical surface 426B in which indicia may be provided, such as by etching. The indicia may include identification information about the nozzle 400E, such as its part number, its intended usage, etc. Below the cylindrical surface 426B, the outer surface 414E also includes another cylindrical surface 426E.Attorney Docket No. 1485.1086i2PATENTCylindrical surface 426E includes several grooves 472E that are formed in a knurled pattern 470E in which the grooves are formed in a diamond-shaped pattern. The grooves 472E provide a gripping surface for a user to grasp and manipulate the nozzle 400E. In addition, the grooves 472E provide an increased surface area pattern that enhances the cooling effect of air passing along outer surface 414E. Below cylindrical surface 426E is a convergent section 416E that tapers to the distal end 43 OE.

[0159] Turning to FIG. 18B, the knurled pattern 470E of the grooves 472E in outer surface 414E is shown in cross-section. Nozzle 400E has a bore 434E with an inner tapered bore portion 437E, a central bore portion 436E with a cylindrical profile, and an outer bore portion 435E that has an inner diameter that is larger than the inner diameter of the central bore portion 436E. The outer bore portion 435E terminates in an orifice 438E at the outer end thereof, which is located in the distal end 430E of the nozzle 400E. The relative lengths of the portions of bore 434 are shown in FIG. 18B as well. Central bore portion 436E has a length dimension “b5”. The outer bore portion 435E has a length dimension “a5”, which is slightly greater than the length dimension “c5” of inner bore portion 437E. The inner diameter “e5” of outer bore portion 435E is larger than the inner diameter “d5” of the central bore portion 436E.

[0160] Turning to FIGS. 19 and 20, a nozzle that is used for a gouging operation is illustrated. In this embodiment, the nozzle 400F is exemplary of a nozzle that can be used for a 70 Amp gouging operation. Referring to FIG. 19, the nozzle 400F has a proximal end 41 OF and an opposite distal end 43 OF. The distal end 43 OF has a sleeve or extension 480F with a smaller outer diameter.

[0161] Turning to FIG. 20, a cross-sectional side view of the nozzle 400F is illustrated. Nozzle 400F has a bore 434F that has a different configuration than the bores in the previously described embodiments. The bore 434F has an inner tapered bore portion 437F that resembles the other inner tapered bore portions and has a similar length “c6” to them. However, the bore 434F has a different central bore portion 436F and a different outer bore portion 435F. As shown, the length “a6” of the outer bore portion 435F is greater than the length “b6” of the central bore portion 436F. Also, the inner diameter “e6” of outer bore portion 435F is much larger than the inner diameter “d6” of the central bore portion 436F. The outer bore portion 435F terminates in an orifice 438F at the outer end thereof, which is located in the extension 480F of the nozzle 400F.Attorney Docket No. 1485.1086i2PATENT

[0162] Turning to FIG. 21, another embodiment of a nozzle that is used for a gouging operation is illustrated. Nozzle 400G is exemplary of a nozzle that can be used for a 90 Amp gouging operation. Nozzle 400G has a distal end 430G that includes an extension 480G and a bore 434G. The bore 434G has an inner tapered bore portion 437G with a length “c7”. The bore 434G has a central bore portion 436G with a length “b7” and a width “d7” that is greater than the width “d6” of central bore portion 435F of nozzle 400F. The outer bore portion 435G has a length “a7” and a width “e7” that is greater than the width “e6” of the outer bore portion 435F of nozzle 400F. The outer bore portion 435G terminates in an orifice 438G at the outer end thereof, which is located in the extension 480G of the nozzle 400G.

[0163] Referring to FIGS. 21A, 21B, and 21C, another embodiment of a nozzle according to the present disclosure is illustrated. FIG. 21A is a side view, FIGS. 21B is an exploded side view, and FIG. 21C is a cross-sectional exploded side view of nozzle 1600. In this embodiment, nozzle 1600 includes an upper portion 1610 and a lower portion 1650 which is removably coupled to the upper portion 1610. When a lower portion 1650 of the nozzle 1600 needs to be replaced, the lower portion 1650 can be removed from the upper portion 1610 and a different, new lower portion 1650 can be coupled to the upper portion 1610. An outer surface of the lower portion 1650 can have a knurled pattern of grooves formed thereon that a user can grasp to easily remove the lower portion 1650 from the upper portion 1610.

[0164] The upper portion 1610 has a proximal end 1612 and a distal end 1614 opposite to proximal end 1612. The lower portion 1650 has a proximal end 1652 (shown in FIGS. 21B and 21C) and a distal end 1654 opposite to proximal end 1652. Proximate to proximal end 1652 is a ledge 1670 that engages the distal end 1614 ofthe upper portion 1610 when the lower portion 1650 is coupled to the upper portion 1610.

[0165] Referring to FIGS. 21B and 21C, the distal end 1614 and the proximal end 1612 of the upper portion 1610 of the nozzle 1600 are shown. An outer surface 1616 and an inner surface 1618, each of which having various different portions, extend between the proximal end 1612 and the distal end 1614. Upper portion 1610 has a connection portion 1620 to which the lower portion 1650 is coupled. The connection portion 1620 includes an inner surface section 1622 that has several threads formed therein.Attorney Docket No. 1485.1086i2PATENT

[0166] For the lower portion 1650, the distal end 1654 and the proximal end 1652 of the lower portion 1650 of the nozzle 1600 are also shown. An outer surface 1656 and an inner surface 1658, each of which having various different portions, extend between the proximal end 1652 and the distal end 1654. Lower portion 1650 has a connection portion 1660 that is coupled to connection portion 1620 of the upper portion 1610. Connection portion 1660 has a threaded outer surface 1662 that can be inserted into connection portion 1620. As mentioned above, ledge 1670 engages the distal end 1614 of the upper portion 1610 when threaded outer surface 1662 engages the threaded inner surface 1622.

[0167] In one embodiment, the splitting of the nozzle into upper and lower portions is satisfactory for lower amperages, such as 30Amp, 40 Amp, and 50Amp. At higher amperages, the joint between the two portions of the nozzle becomes hot.

[0168] Referring to FIGS. 21D and 21E, another embodiment of a nozzle according to the present disclosure is illustrated. In this embodiment, nozzle 1700 includes an upper portion 1710 and a lower portion 1750 which is removably coupled to the upper portion 1710. When a lower portion 1750 of the nozzle 1700 needs to be replaced, the lower portion 1750 can be removed from the upper portion 1710 and a different, new lower portion 1750 can be coupled to the upper portion 1710. An outer surface of the upper portion 1710 can have a knurled pattern of grooves formed thereon that a user can grasp to easily remove the lower portion 1750 from the upper portion 1710.

[0169] The upper portion 1710 has a proximal end 1712 and a distal end 1714 opposite to its proximal end 1712. The lower portion 1750 also has a proximal end 1752 and a distal end 1754 opposite to its proximal end 1752. The upper portion 1710 has a ledge 1730 that engages the proximal end 1752 of the upper portion 1710 when the lower portion 1750 is coupled to the upper portion 1710.

[0170] As shown in FIG. 21E, for nozzle 1700, the distal end 1714 of the upper portion 1710 is located inside of the proximal end 1752 of the lower portion 1750, which is the opposite arrangement shown in FIG. 21C for nozzle 1600 where the proximal end 1652 of the lower portion 1650 is located inside of the distal end 1614 of the upper portion 1610.

[0171] Upper portion 1710 has a connection portion 1720 to which the lower portion 1750 is coupled. The connection portion 1720 includes an outwardly directed surface section 1722 thatAttorney Docket No. 1485.1086i2PATENThas several threads formed therein. Lower portion 1750 has a connection portion 1760 that is coupled to connection portion 1720 of the upper portion 1710. Connection portion 1760 has an inwardly directed surface section 1762 that has several threads formed therein and that can be inserted into connection portion 1720. Ledge 1730 engages the proximal end 1752 of the lower portion 1750 when threaded surface 1762 of lower portion 1750 is engaged with and coupled to threaded surface 1722 of upper portion 1710. In this arrangement, the splitting of the nozzle into upper and lower portions is satisfactory for higher amperages because of the arrangement of the threaded surfaces 1722 and 1762 with the upper portion 1710 extending inside of the lower portion 1750.

[0172] Turning to FIGS. 22-25, various views of an example embodiment of a shield are illustrated. Shield 600 is an example embodiment of a shield that can be used in different amperage operations.

[0173] Referring to FIGS. 22-24 initially, the shield 600 has a proximal end 610 and a distal end 620 opposite to the proximal end 610. The shield 600 is sized so that one of the previously described nozzles can be inserted into a cavity of the shield 600. Adjacent the proximal end 610 is a proximal portion 612, and adjacent the distal end 620 is a distal portion 622. As shown in FIGS. 22 and 23, the shield 600 has an opening or orifice 624 formed in the distal end 620 that is fluidically coupled to an internal cavity 680 of the shield 600.

[0174] In this embodiment, the outside of the shield 600 has two different parts (see FIG.24). One part is a cylindrical portion 630 that includes the proximal portion 612 of the shield 600. The other part is an angled or tapered portion 660 that includes the distal portion 622 of the shield 600. The cylindrical portion 630 extends to the angled portion 660. The cylindrical portion 630 has an outer surface 632 that extends to an outer surface 662 of angled portion 660. As shown in FIGS. 23 and 24, the outer surface 662 has several openings 674 formed therein around the perimeter of the shield 600. Referring back to FIG. 22, the shield 600 includes an internal ledge 654 that extends around an inner perimeter of the shield 600. The ledge 654 has several openings 670 formed therein that are spaced apart from each other, each of which is in communication with one of the openings 674 in outer surface 662.Attorney Docket No. 1485.1086i2PATENT

[0175] Turning to FIG. 25, a cross-sectional view showing the various features of the shield 600 is illustrated. The proximal end 610 and the opposite distal end 620 are shown. The cylindrical portion 630 has an inwardly extending flange 640 that has an inner surface 634. The inner surface 634 extends between an upper ledge 642 of the flange 640 to a lower edge 643 of the flange 640. The upper ledge 642 has a beveled or chamfered edge. The lower edge 643 of the flange 640 in combination with a lower ledge 644 and an inner wall 650 collectively define an inner groove 652. As shown in FIG. 57, the inner flange 640 extends into a groove formed in the proximal shield cup member 770. Returning back to FIG. 25, the shield 600 also has an inner cylindrical surface 668 that extends distally to another inner ledge 654.

[0176] The shield 600 has an inner surface 664 that is angled up to a tip or end 666. The various inner surfaces and ledges collectively define the internal cavity 680 of the shield 600 which extends to orifice 624. As mentioned above, openings 670 are formed in the ledge 654 and openings 674 are formed in outer surface 662. Each pair of openings 670 and 674 is located at opposite ends of a passageway 672 and are in fluid communication with each other. Each passageway 672 extends through the wall of the shield 600 and, in this embodiment, extends parallel to a longitudinal axis of the shield 600. A shield gas can enter an opening 670, travel through a passageway 672, and exit an opening 674 out of the shield 600.

[0177] The foregoing discussion relates to various components of a consumable cartridge. Now turning to FIG. 26, an example embodiment of a torch head assembly is illustrated and described. Torch head assembly 900 includes a shield 600, a distal shield cup member 710, and a cylindrical insulator 800. The distal shield cup member 710 is made of metal and is conductive. The cylindrical insulator 800 is made of an insulative material. In addition, the torch head assembly 900 includes a torch head fitting 920 with a passageway 921, torch head components 1000 and 1200, and an arc initiator 1300.

[0178] In one alternative embodiment, one of the torch head components may include an opening formed therein through which a camera tube or housing (not shown) extends. The camera housing can receive a camera therein that is positioned to read and identify indicia on a consumable cartridge, which is used to confirm that an appropriate consumable cartridge is inserted. In addition, one of the torch head components also includes an opening formed therein through which a sensor probe may extend. The sensor probe extends from the torch head assembly toward theAttorney Docket No. 1485.1086i2PATENTconsumable cartridge. When a consumable cartridge is inserted into the torch head assembly, the consumable cartridge presses on the sensor probe, which closes a switch when the proper consumable cartridge has been inserted.

[0179] Torch head component 1100 also has an open central portion in which a torch head fitting 920 is positioned. The torch head fitting 920 includes a central passageway in which the proximal portion of the electrode 200 is located. Beneath torch head component 1100 is another torch head component 1000, which is described in greater detail below.

[0180] Turning to FIG. 27, an exploded perspective view of several components of the torch head assembly 900 is illustrated. Tn this embodiment, the torch head assembly 900 includes a shield 600, a distal shield cup member 710, an insulator 800, a proximal shield cup member 770 that is located in the insulator 800, and torch head components 1000, 1100, and 1200, each of which is described below. The proximal shield cup member 770 is made of metal and is conductive.

[0181] Referring to FIGS. 28 and 29, different views of a few of the torch head components are illustrated. In FIG. 28, which is a proximal end perspective view, torch head component 1200 is located inside torch head component 1000 and extends outwardly from both ends of torch head component 1000. Torch head component 1100 is located inside of both torch head component 1000 and torch head component 1200. An arc initiator 1300 extends from the proximal end of torch head component 1000. Also shown in FIG. 28 is an O-ring 1400, which is described below. In FIG. 29, which is a perspective view, the distal end 1106 of torch head component 1100 is shown. The arc initiator 1300 extends through torch head component 1100 and around a portion of a groove formed in the distal end 1106 of torch head component 1100. Torch head component 1200 has a distal end 1254 that has several openings 1255 extending therethrough.

[0182] Referring to FIGS. 30 and 31, different views of arc initiator 1300 are shown. In this embodiment, arc initiator 1300 has a linear portion 1310 with a proximal end 1312 and a distal end 1314 that extends through torch head component 1100. Arc initiator 1300 also has a curved portion 1320 that is coupled to linear portion 1310 and that has opposite ends 1322 and 1324. Integrally formed with curved portion 1320 is an end portion 1330.Attorney Docket No. 1485.108612PATENT

[0183] Referring to FIG. 32, an exploded perspective view of torch head components 1000, 1100, and 1200 is illustrated. Each of the torch head components 1000, 1100, and 1200 has an inner surface that defines a passageway or cavity that extends between the opposite ends of the particular torch head component. Torch head component 1100 has a passageway 1122 extending therethrough. Similarly, torch head component 1200 has a passageway 1224 extending therethrough. Also, torch head component 1000 has its own passageway 1028 extending therethrough. In this embodiment, torch head component 1000 is configured to receive at least a portion of each of the other torch head components 1100 and 1200. Torch head component 1200 is inserted into the cavity of torch head component 1000, such as via the opening at the lower or distal end of torch head component 1000. The result is that a portion of torch head component 1200 is seated within torch head component 1000 as described below. Torch head component 1100 is inserted into torch head component 1200 via the opening at the lower or distal end of torch head component 1200. In addition, torch head component 1100 is also positioned into of torch head component 1200. A cross-sectional view of the torch head components 1000, 1100, and 1200 in their assembled configuration is illustrated in FIG. 34, which will be described in greater detail below.

[0184] In this embodiment, torch head component 1200 has a portion with a hole or opening 1277 extending therethrough. Similarly, torch head component 1100 has a portion with a hole 1170 extending therethrough. When the torch head components 1000, 1100, and 1200 are coupled together, a connector 1420, such as a screw, passes through the holes 1277 and 1170 to secure the torch head components 1000, 1100, and 1200 relative to each other. Referring to FIG.33, the screw 1420 has an end 1422 with an opening 1423 formed therein and an outer surface that has several threads 1424 formed thereon.

[0185] Referring to FIG. 34, a vertical cross-sectional view of the assembled torch head components 1000, 1100, and 1200 is illustrated. Torch head component 1100 is located inside of the other torch head components 1000 and 1200. Torch head component 1100 has an inner surface 1110 that defines the cavity or passageway 1122 extending through torch head component 1100. Torch head component 1100 also has an outer surface 1160 that has agroove or recess 1162 formed therein. Torch head component has several openings and passageways, which are described in detail relative to FIG. 45, through which a gas can flow along the directions of the arrows in FIG.Attorney Docket No. 1485.1086i2PATENT34. Torch head component 1100 has a groove 1164 that extends around the outer perimeter thereof. The groove 1164 is configured to receive an O-ring 1410 therein. The O-ring 1410 is located between torch head component 1100 and torch head component 1200 and prevents any gas from traveling between the surfaces of those components 1100 and 1200.

[0186] In the cross-sectional view illustrated in FIG. 34, only a portion of torch head component 1200 is shown. The structure and features of torch head component 1200 are illustrated in FIGS. 39-41. In FIG. 34, torch head component 1200 has a body 1210 that has an upper end 1220 and an opposite lower end 1222. Extending through the body 1210 are a series of horizontal openings 1240 that are in communication with passageways 1242. The openings 1240 and the passageways 1242 are configured so that a gas can flow therethrough along the directions of the arrows in FIG. 34. In particular, some of the gas flowing through openings in torch head component 1100 also flows through openings 1240 and passageways 1242. Torch head component 1200 also includes several other passageways (see FIGS. 41 and 57) through which gas flow portions 1530 and 1540 pass along the direction of the corresponding arrows in FIG. 34. The body 1210 of torch head component 1200 includes a groove 1234 that extends around the outer perimeter of the body 1210. Disposed in the groove 1234 is an O-ring 1400.

[0187] Torch head component 1000 has a proximal end 1002 and a distal end 1006 opposite to the proximal end 1002. The torch head component 1000 also has an inner surface 1020 that defines passageway 1028. The inner surface 1020 includes a ledge 1022 that is abutted by the proximal end of torch head component 1100, and an inwardly extending ridge 1024 that engages the groove or recess 1162 in torch head component 1100. The engagement of ridge 1024 with groove or recess 1162 ensures that torch head component 1100 is in its correct position within torch head component 1000.

[0188] Now turning to FIGS. 35-38, various views of torch head component 1000 are illustrated. Referring to FIG. 35, the proximal end 1002 and the distal end 1006 of the torch head component 1000 are shown. Proximate to proximal end 1002 is a gap 1055. In FIG. 36, a top perspective view of torch head component 1000 is illustrated. As can be seen, the proximal end 1002 has two gaps located on opposite sides of the torch head component 1000. Gap 1055 is essentially a notch out of the side wall on one side. At gap 1055, an outer portion 1050, which is a wall, defines a slot 1057 between it and an outer surface of a wall portion 1059. Opposite to gapAttorney Docket No. 1485.1086i2PATENT1055 is another gap 1035 that is a notch out of a side wall on that side of the torch head component 1000. At gap 1035, an outer portion 1030, which is a wall, defines a slot 1037 between it and an outer surface of a wall portion 1039.

[0189] Referring to FIG. 37, a bottom perspective view of torch head component 1000 is illustrated showing the distal end 1006. The torch head component 1000 has two opposing body portions 1010 and 1012. On one side, formed between body portions 1010 and 1012 is the wall 1030. On the opposite side, wall 1050 is also formed between body portions 1010 and 1012. Slots 1037 and 1057 located inside of walls 1030 and 1050, respectively, are shown as well. Coupled to the inner surface of wall 1030 is a post 1040 about which a spring 1042 is placed. The spring 1042 is referred to alternatively as a cage. Located at one end of spring 1042 is a protrusion 1070 that extends into the passageway 1028.

[0190] A cross-sectional side view of torch head component 1000 is illustrated in FIG. 38. Located near the proximal end 1002 is a proximal portion 1004 and located near the distal end 1006 is a distal portion 1008. The body of the torch head component 1000 has a longitudinal axis 1005 that extends from the proximal end 1002 to the distal end 1006. Torch head component 1000 has an inner portion 1060 with an outer surface 1062 and an opposite inner surface 1064. The inner surface 1064 defines in part the passageway 1028 along with other inner surfaces. Below surface 1064 is the previously described ledge 1022 and the inwardly extending ridge 1024. Below the ridge 1024 is the protrusion 1070 that has a cavity 1072 with a surface 1074 containing threaded grooves 1076. The cavity 1072 and the threaded grooves 1076 are configured to receive screw 1420 and its threads 1424. Aligned with the protrusion 1070 is post 1040 and spring 1042.

[0191] Outer portion 1030 has an outer surface 1032 and an inner surface 1034 opposite to outer surface 1032. As shown, post 1040 is integrally formed with and extends inwardly from the inner surface 1034 of outer portion 1030. Outer portion 1030 has an upper end 1036 and a lower end 1038 opposite to upper end 1036. The length of outer portion 1030 between upper end 1036 and lower end 1038 is less than the length of torch head component 1000 between proximal end 1002 and distal end 1006. As a result, the proximal end 1002 and distal end 1006 are located beyond each of the upper end 1036 and the lower end 1038. The outer portion 1030 is configured so that it is spaced apart from the main body of the torch head component 1000, thereby forming slot 1037 therebetween.Attorney Docket No. 1485.1086i2PATENT

[0192] Similarly, outer portion 1050 has an outer surface 1052 and an inner surface 1054 opposite to outer surface 1052. Outer portion 1050 has an upper end 1056 and a lower end 1058 opposite to upper end 1056. The length of outer portion 1050 between upper end 1056 and lower end 1058 is less than the length of torch head component 1000 between proximal end 1002 and distal end 1006. As a result, the proximal end 1002 and distal end 1006 are located beyond each of the upper end 1056 and the lower end 1058. The outer portion 1050 is configured so that it is spaced apart from the main body of the torch head component 1000, thereby forming slot 1057 therebetween.

[0193] Now turning to FIGS. 39-41, different views of torch head component 1200 are illustrated. Torch head component has a proximal portion 1202 near proximal end 1204 that is formed by two arcuate extensions, and has a distal portion 1206 near distal end 1208 that is formed by a generally cylindrical or circular body 1210. Extending from body 1210 is an extension 1250 that is generally curved and that extends along only a portion of body 1210. Also extending from body 1210 is an extension 1270 that is generally curved and that extends along only a portion of body 1210. On one side of torch head component 1200, the extensions 1250 and 1270 are spaced apart from each other by a gap 1264. Similarly, on the other side of torch head component 1200, the extensions 1250 and 1270 are spaced apart from each other by a gap 1284.

[0194] Located at the proximal end of extension 1250 are flange portions 1260 and 1262 that are spaced apart from each other by a space 1265. In this embodiment, flange portions 1260 and 1262 have different shapes. Flange portion 1260 is thicker and longer than flange portion 1262 which is planar. The flange portions 1260 and 1262 are spaced apart from the body 1210 by a gap 1251, which is located along the extension 1250.

[0195] Located at the proximal end of extension 1270 are flange portions 1280 and 1282 that are spaced apart from each other by a space 1285. Flange portions 1280 and 1282 are generally similar in size and shape to each other, and are also similar in size and shape to flange portion 1260. The flange portions 1280 and 1282 are spaced apart from the body 1210 by a gap 1271, which is located along the extension 1270.

[0196] As previously mentioned, torch head component 1200 has opening 1277 formed therein through which the protrusion 1070 and screw 1420 can extend. Also shown in FIG. 39 isAttorney Docket No. 1485.1086i2PATENTa through opening 1240, which is one of several spaced apart openings 1240 that are described in detail below.

[0197] Turning to FIG. 40, a distal end perspective view of torch head component 1200 is illustrated. In this view, the outside surface of extension 1250 is shown, with the differences between flange portions 1260 and 1262 being evident. The space 1265 between flange portions 1260 and 1262 along with the gap 1251 are illustrated. The width of extension 1270 from side-to-side is larger than the width of extension 1250 from side-to-side. In this perspective, both opening 1240 and opening 1277 are visible. The distal end 1208 has several spaced apart exit openings 1248 located about its perimeter.

[0198] A cross-sectional side view of torch head component 1200 is illustrated in FIG. 41. Turning first to the body 1210, the body 1210 has an outer surface 1212 and an opposite inner surface 1214. An inwardly extending radial ledge 1216 is formed on the inner surface 1214 of the body 1210. As shown back in FIG. 34, the ledge 1216 engages a notch in the distal end of torch head component 1100 that extends around the perimeter thereof. The engagement of ledge 1216 with the notch prevents torch head component 1100 from moving relative to torch head component 1200.

[0199] Several spaced apart openings 1240 are formed in and extend through the body 1210. Each of the openings 1240 is in communication with a passageway 1242 extending through the body 1210. A channel 1243 is formed around the perimeter of the body 1210. The channel 1243 is in communication with each of the passageways 1242. In one embodiment, each of the opening 1240 and passageway 1242 combinations is spaced apart from the other ones of the opening 1240 and passageway 1242 combinations by approximately 90 degrees. The body 1210 has several spaced apart passageways 1246 that extend along the direction of a longitudinal axis of torch head component 1200. At one end of each passageway 1246 is an opening 1244 that is in communication with the channel 1243. At the opposite end of each passageway 1246 is an opening 1248. As a result, gas can flow into an opening 1240, through a passageway 1242, into the channel 1243, into an opening 1244, through a passageway 1246, and exit the passageway 1246 through an opening 1248, which is proximate to lower end 1222.Attorney Docket No. 1485.1086i2PATENT

[0200] Toward the upper end of the body 1210 are flanges 1230 and 1232 that extend around the perimeter of the body 1210. The flanges 1230 and 1232 extend radially outwardly and define groove 1234 therebetween. The groove 1234 receives O-ring 1400 as shown in FIG. 34.

[0201] Extension 1250 has a proximal end 1252 and an opposite distal end 1254. The thickness of the extension 1250 between ends 1252 and 1254 varies. Extension 1250 has an inner surface 1256 and an opposite outer surface 1258. A portion of the extension 1250 has a stepped feature formed therein. Next to the flange portions 1260 and 1262, the extension 1250 has a groove 1259.

[0202] Extension 1270 also has a proximal end 1272 and an opposite distal end 1274. The thickness of the extension 1270 between ends 1272 and 1274 varies. Extension 1270 has an inner surface 1276 and an opposite outer surface 1278. A portion of the extension 1270 has a stepped feature formed therein. Next to the flange portions 1280 and 1282, the extension 1270 has a groove 1279. In addition, at the distal end 1274 of extension 1270 is hole 1277 extending through the body 1210.

[0203] Turning to FIGS. 42-45, different views of torch head component 1100 are illustrated. Torch head component 1100 has a proximal end 1102 with a proximal portion 1104 and a distal end 1106 with a distal portion 1108. The outer surface 1160 has the through hole 1170 and a groove 1162 extending around its perimeter. In addition, the outer surface 1160 has a radially extending flange 1165 defining a groove 1164. On the other side of the flange 1165 is another groove 1166. Located at spaced apart points within groove 1166 are openings 1124.

[0204] FIGS. 43 and 44 are a top perspective view and a bottom perspective view of torch head component 1100, respectively.. Torch head component 1100 has an opening 1103 formed in the proximal end 1102. The torch head component 1100 is generally cylindrical with an inner surface 1132 that defines an internal through passageway 1128, which is in communication with hole 1170. In FIG. 44, in the distal end 1106 is a circular groove or slot 1150 formed therein. An opening 1152 is in communication with opening 1103 via a passageway (not shown in FIG. 44). In addition, another opening 1154 is provided in torch head component 1100.

[0205] Referring to FIG. 45, a cross-sectional view of torch head component 1100 is illustrated. An inner surface 1110 has an inwardly extending flange 1112 that has a ledge 1114.Attorney Docket No. 1485.1086i2PATENTLocated at several locations around the inside of surface 1110 are several openings 1120. Each of the openings 1120 is at one end of a passageway 1122. Each passageway 1122 extends to an opening 1124 that is on the outer end of the passageway 1122. Each passageway 1122 has an opening 1126 located therealong that is in communication with another passageway 1128.

[0206] Located proximate to the distal end 1106 are an inner portion 1130 and an outer portion 1140 that define therebetween a slot 1150. The torch head component 1100 has an outer portion 1140 that has an inner surface 1142 and an outer surface 1144 opposite to surface 1142. Extending outwardly from outer surface is a flange 1146. Torch head component 1100 also has an inner portion 1130 that is spaced apart from the outer portion 1140. Inner portion 1130 has an inner surface 1132 that has several grooves 1134 extending therealong, and an outer surface 1136 that is opposite to the inner surface 1132. The passageways 1128 are spaced apart in communication with the slot 1150.

[0207] Turning to FIGS. 46 and 47, different views of several components are illustrated. Starting at the bottom of FIG. 46, a shield cup assembly 700 includes a distal shield cup member 710 that is proximate to an insulator 800. In this embodiment, the shield cup assembly 700 includes several different parts. In particular, as shown in FIG. 47, the shield cup assembly 700 includes the distal shield cup member 710 and a proximal shield cup member 770. When the distal shield cup member 710 is engaged with the insulator 800, the proximal shield cup member 770 is located inside of the distal shield cup member 710 and the insulator 800. The distal shield cup member 710 has a body portion 720 and an extending portion 722.

[0208] The proximal shield cup member 770 has a proximal end 772 that defines an opening 774, and a distal end 780 that has an angled portion 782. In this embodiment, the outer surface 786 of the proximal shield cup member 770 has several spaced apart grooves 788 between the proximal end 772 and the angled portion 782.

[0209] The insulator 800 has a proximal end 802 and a distal end 806 opposite to the proximal end 802. The insulator 800 has an inner surface 810 that defines a passageway 812. An outer surface 830 is generally continuous and cylindrical other than the part near the distal end 806. That part includes a grooved portion 832 defined between the outer surface 830 and a ridge 834. Below the ridge 834 is an angled portion 836.Attorney Docket No. 1485.1086i2PATENT

[0210] Turning to FIG. 48, the exploded arrangement of the distal shield cup member 710, the proximal shield cup member 770, and the insulator 800 is shown in cross-section. The distal shield cup member 710 has a proximal end 712 that defines an opening 714 and an opposite distal end 716 that defines an opening 718 that is small than opening 714. An inner ridge 730 extends around the inner perimeter of the distal shield cup member 710. Spaced apart grooves 732 are located along the inner ridge 730. Below the inner ridge 730 is a recessed area 734 and an angled surface 736. The angled surface terminates at a ledge 738 below which is the extending portion 722. The outer diameter of the extending portion 722 is smaller than the outer diameter of the remainder of the distal shield cup member 710. The inside of the extending portion 722 is an angled surface 740 and a cylindrical surface 742.

[0211] Turning to the proximal shield cup member 770, the various inner surfaces are illustrated in FIG. 48. An inner surface 776 extends from the proximal end 772 and is parallel to a longitudinal axis of the proximal shield cup member 770. Member 770 also has an inwardly extending flange 777 located between the inner surface 776 and a groove 778. The lower or distal end of the groove 778 transitions to an angled surface 779. Below the angled surface 779 is an inner wall 790 that defines a ledge 796. The inner wall 790 also defines an opening 784 at the end of the angled portion 782 at the distal end 780. In addition, the inner wall 790 has several openings 792 formed therein, each of which is located at the end of a respective passageway 794. The openings 792 and passageways 794 are sized to receive and have fluid pass therethrough.

[0212] In this embodiment, the insulator 800 has one opening 804 located at the proximal end 802 and another opening 808 located at the distal end 806. The inner surface 810 defining part of the passageway 812 extends to an edge 814 that is at the start of another inner surface 816 that has a slightly larger inner diameter than inner surface 810. Inner surface 816 terminates at an angled surface 818. The angled surface 818 is connected to a ledge 819 that in turn ends at a wall 820 that is parallel to a longitudinal axis of insulator 800. Wall 820 defines opening 808 as shown.

[0213] On the outside of insulator 800, there is an outer surface 830 that has a generally cylindrical profile and that extends nearly the full length of the insulator 800. As described above relative to FIG. 47, close to the distal end 806, the outer surface includes the grooved portion 832, a ridge 834, and an angled portion 836.Attorney Docket No. 1485.1086i2PATENT

[0214] Turning to FIG. 49, when the insulator 800 is coupled to the distal shield cup member 710, the proximal shield cup member 770 is inserted into the insulator 800. The inner ridge 730 of the distal shield cup member 710 engages the grooved portion 832 of the insulator 800. At the same time, the ridge 834 on insulator 800 engages the recessed area 734 of the distal shield cup member 710. The distal end 806 contacts and is flush with ledge 738 of the distal shield cup member 710.

[0215] The proximal shield cup member 770 is inserted into the cavity or passageway of the insulator 800. The proximal shield cup member 770 is positioned so that its distal end 780 engages the ledge 819 of the insulator 800. The outer profile of the distal shield cup member 770 matches the lower portion of the inner profile of the insulator 800. As a result, the proximal shield cup member 770 is snugly positioned within the insulator between the distal end 806 and the edge 814 at the end of inner surface 816. When the distal shield cup member 710 is mounted onto the insulator 800 and the proximal shield cup member 770 is placed in the insulator 800, the openings 792 formed in wall 790 are free so that any fluid can pass therethrough. The openings 792 are located so that a fluid traveling through passageways 794, exits openings 792 and travels through opening 808 of insulator 800 and then through opening 718 of distal shield cup member 710.

[0216] Turning to FIGS. 50 and 51, a top perspective view and a top view of the proximal shield cup member 770 are illustrated. As described above, the flange 777 is located above the ledge 796. The ledge 796 has several openings 798 formed therein, each of which is an inlet opening to a passageway 794. Each of the openings 792 formed in the inner wall 790 is an outlet opening for a passageways 794. Openings 792 are oriented to be in fluid communication with the opening 784 of the distal end 780. The grooves 788 in the outer surface 786 are also visible in both views.

[0217] Turning to FIG. 52, a top perspective view of the distal shield cup member 710 is illustrated. The spaced apart grooves 732 along ridge 730 are shown. The various inner surfaces of the distal shield cup member 710 include the angled surface 736, the ledge 738, the angled surface 740, and the cylindrical surface 742, which defines the opening 718.

[0218] Referring to FIG. 53, a perspective view of a spring 940 is illustrated. The spring 940 is a resilient member that receives a portion of the electrode 200. The spring 940 has oppositeAttorney Docket No. 1485.1086i2PATENTend portions 942 and 944 and a middle portion 946 between the end portions. The middle portion 946 has numerous resilient members 948, each of which has a curved configuration that defines an inner diameter of the middle portion 946 that is smaller than the inner diameter of each of the end portions 942 and 944.

[0219] In FIG. 54, a perspective view of the torch head fitting 920 is shown. Torch head fitting 920 is an elongate member that defines an internal channel or passageway 921 that extends along the longitudinal axis of the fitting 920. The fitting 920 has an outer surface 922 that has several different sections with varying outer diameters. In particular, the outer surface 922 includes a flange 923 that defines a groove 924 adjacent thereto. In addition, the outer surface 922 defines another groove 925 as shown. O-ring 930 is mountable on the torch head fitting 920.

[0220] Turning to FIG. 55, a cross-sectional view of torch head fitting 920 is shown. Torch head fitting 920 includes a passageway 921 therethrough in which the spring 940 can be placed. O-ring 930 is locatable in groove 924 beneath flange 923. The other groove 925 in the outer surface 922 is shown as well.

[0221] Referring to FIGS. 55A and 55B, cross-sectional side views of some torch components are illustrated. In FIG. 55A, the electrode 200 is shown in a first or intermediate position 201 A in which the proximate end 210 of the electrode 200 is proximate to the spring 940, which is also a contact band. The electrode 200 is moved or slid along the direction of arrow “A” in FIG. 55A when the DCM is coupled to the torch head. Referring to FIG. 55B, the electrode 200 has been inserted so that the proximal end 210 is located inside of the spring or contact band 940, with the electrode 200 being in a second or inserted position 20 IB. Thus, due to the shape of the spring 940, the electrode 200 can move and still maintain contact with the spring or contact band 940.

[0222] Turning to FIG. 56, a sensor probe 950 is illustrated. The sensor probe 950 includes a central body portion 952 that has a generally cylindrical outer profile. At opposite ends of the central body portion 952 are end portion 954 and head 958. Beneath the head 958 is a collar 956. The sensor probe 950 is positioned so that when a consumable stack is inserted or mounted to the torch head, the consumable stack engages and presses the sensor probe 950 to move the sensor probe 950 along its longitudinal axis 955. When the sensor probe 950 is moved, it engages andAttorney Docket No. 1485.1086i2PATENTcloses a switch located in the torch head. The sensor probe 950 is moved only by an appropriate consumable stack. In other words, when an incorrect (such as from an incorrect consumable stack is inserted into a torch head, the sensor probe 950 will not be moved, and the switch will not be closed. The sensor probe 950 is used to confirm that the appropriate consumables for a particular torch head are used.

[0223] Referring to FIG. 57, a cross-sectional view of torch head assembly 900 is illustrated. The shield 600 is coupled to the extending portion 722 of the distal shield cup member 710. As discussed above, the proximal shield cup member 770 is located inside of the insulator 800. The various fluid flows are shown by the arrows drawn in FIG. 57. A fluid flow 1500, which in this embodiment is a gas, is shown entering the proximal end of torch head fitting 920. The fluid flow 1500 enters the passageway 921 of fitting 920 and then enters the channel 216 of the electrode 200. The fluid flow 1500 travels to the distal end 220 of the channel 216 and travels outward through the openings 222. At this point, the fluid flow 1500 is split into multiple different flow portions. Flow portion 1510 and flow portion 1520 are routed to be plasma gas flows that are directed to the plasma chamber . Flow portion 1530 and flow portion 1540 are shield gas flows that are directed to the shield 600 .

[0224] Turning to the shield gas flow portions 1530 and 1540 first, a portion of the fluid exiting openings 222 of the electrode 200 travels through passageways 1122 formed in torch head component 1100 and outward through openings 1124. Adjacent to the torch head component 1100 is torch head component 1200. The gas flows then travel through openings 1240 into passageways 1242 formed in the wall of torch head component 1200, and through passageways 1246 formed in the wall of torch head component 1200. The gas flow portions 1530 and 1540 then travel through passageways 794 in proximal shield cup member 770. Upon exiting the passageways 794, the gas flow portions 1530 and 1540 travel through the opening 784 in proximal shield cup member 770, the opening 808 in insulator 800, and the opening 718 in distal shield cup member 710 at this point, upon exiting opening 718, the gas flow portions 1530 and 1540 have reached the internal cavity 680 of the shield 600. A portion of the gas flow portions 1530 and 1540 travels through the passageways 672 of the shield 600 and exits the shields as gas flow portions 1534 and 1544. The other portion of the gas flow portions 1530 and 1540 travels along the inner surface 664 of the shield 600 and out through the orifice 624 as gas flow portions 1532 and 1542.Attorney Docket No. 1485.1086i2PATENT

[0225] Now turning to the plasma gas flow portions 1510 and 1520, the other portion of the fluid exiting openings 222 of the electrode 200 travels along the ribbed outer surface of the outer surface of the electrode 200 and enters the gas distributor 300. The gas flow portions 1510 and 1520 travel through passageways 362 in the gas distributor 300 and exits through openings 324. The gas flow portions 1510 and 1520 travel around the distal end of the electrode 200 between the electrode 200 and the nozzle 400, and then travel through the bore 434 located at the distal end 430 of the nozzle 400 in a combined gas flow portion 1525.

[0226] FIG. 57 also illustrates the various O-rings used in the torch head assembly 900. O-ring 1400 is located between torch head component 1200 and proximal shield cup member 770. O-ring 1410 is located between torch head component 1100 and torch head component 1200. O-ring 270 is located between gas distributor 300 and torch head component 1100. O-ring 272 is located between gas distributor 300 and nozzle 400. Finally, O-ring 930 is located between the torch head fitting 920 and torch head component 1100. The screw 1420 located on post 1040 of torch head component 1000 is shown extending through the opening 1277 in torch head component 1200 and into a recess in torch head component 1100. The combination of the screw 1420 and the post 1040 prevent the relative movement of torch head components 1000, 1100, and 1200.

[0227] In FIG. 58, a slightly different cross-sectional view of the torch head assembly 900 is illustrated. The various components of the torch head assembly 900, including the torch head fitting 920, the electrode 200, and the torch head component 1100 are shown. In this view, the arc initiator 1300 is shown relative to torch head component 1100. A part of each of the linear portion 1310 and the end portion 1330 is located between the inner portion 1130 and the outer portion 1140. The curved portion 1320, which is located between portions 1310 and 1330, is not visible in this view, and is located in the slot 1150 of torch head component 1100.

[0228] Turning to FIGS. 59-61, the valve functions of the torch head assembly are described. The various components of the torch head assembly are designed to balance the cutting or plasma fluid flow and the cooling fluid flow. To achieve this balancing, the torch head assembly has two valve-like functions that are designed to cooperate with each other to control the flow rates of the cutting fluid and the cooling fluid.Attorney Docket No. 1485.1086i2PATENT

[0229] Referring to FIG. 59, a cross-sectional side view of components of a consumable cartridge of a 110 Amp torch is illustrated. The electrode 200 is located inside a nozzle or tip 400E. The nozzle 400E has an outer surface 414E with a knurled groove section 470. The outer surface 414E includes a nozzle or tip shoulder 415E that has an outer diameter. The nozzle 400E also includes a bore 434E with an orifice 438E. Turning to FIG. 60, a cross-sectional side view of components of a consumable cartridge of a 30 Amp torch is illustrated. The electrode 200 is located inside a nozzle or tip 400. The nozzle 400 has an outer surface 414 includes a nozzle or tip shoulder 415 that has an outer diameter. The nozzle 400 also includes a bore 434 with an orifice 438. In different embodiments, the inner diameters of bores 434 and 434E are different from each other, as well as the outer diameters of nozzle shoulders 415 and 415E are different from each other too.

[0230] Turning to FIG. 61, a close-up cross-sectional side view of some components of the 110 Amp torch is illustrated. As referenced in FIG. 59, nozzle 400E has an outer surface 414E with nozzle shoulder 415E. The proximal shield cup member 770 has an inner wall 790 with an opening in communication with passageways 794. The inner wall 790 has an inner diameter dimension and is spaced apart from the nozzle shoulder 415E. There is a distance or gap between inner wall 790 and the nozzle shoulder 415E that can be varied or adjusted in different embodiments.

[0231] The first valve-like function meters or controls the cutting fluid flow through the plasma channels of the torch head assembly. This function is accomplished by varying the size of the inner diameter of the orifice at the bottom of the nozzle, such as orifice 438E of nozzle 400E. The size of the orifice at the bottom of the nozzle can be made either larger to allow more plasma fluid flow therethrough, or smaller to restrict more of the plasma fluid flow traveling therethrough. For different amperages, the nozzle orifice diameters can vary. An exemplary table showing the different inner diameters for nozzles is provided below.Attorney Docket No. 1485.1086i2PATENT

[0232] In addition, the second valve-like function meters or controls the cooling fluid flow of the torch head assembly. This function is determined by the size of the gap between the nozzle shoulder outer diameter, such as shoulder 415E, and the inner wall 790 of the proximal shield cup member 770. The cooling fluid flow rate can be adjusted by varying the size of the gap between those surfaces. In one embodiment, the inner wall 790 diameter is 0.724 inches. An exemplary table showing the different gap dimensions for nozzles is provided below, noting that the gap for the second valve-like function is the difference between the inner wall 790 diameter of 0.724 inches and the diameters below.

[0233] Thus, the combination of adjusting the nozzle orifice inner diameters and the gap between the inner wall of the proximal shield cup member and the nozzle shoulder outer surface enables the metering the gas flow.Attorney Docket No. 1485.1086i2PATENT

[0234] FIG. 62 is another close-up cross-sectional side view of the torch head assembly in FIG. 61. In this view, the proximal shield cup member 770 is located inside of the insulator 800. The outer surface of the insulator 800 has a series of grooves or threads that can engage with the series of grooves or threads on the inner surface of the distal shield cup member 710, which is coupled to the insulator 800. In this view, the inner wall 790 of the proximal shield cup member 770 is shown along with one of the passageways 794 that extend through the lower portion of the proximate shield cup member 770. As mentioned above, the tip or nozzle 400 has a shoulder 415E that has an outer surface spaced apart from inner wall 790. The distance between shoulder 415E and inner wall 790 can be adjusted for different amperage torches to control the air flow through passageways 794 and between shoulder 415E and inner wall 790. This particular air flow is the shield gas flow in the torch. The cutting and cooling air flow rates are balanced by adjusting the spacing between the inner wall 790 and the shoulder 415E as well as the length and diameter of the exit bore of the respective nozzle.

[0235] Several of the outer surface of the distal portion of the electrode 200 are shown. Angled surface 250 and angled surface 254 define therebetween a ridge 252. Angled surface 250 is a conical surface with a proximal end 251 A and a distal end 25 IB that is proximate to ridge 252. Angled surface 250 can be referred to alternatively as a conical surface. As shown, the outer diameter of the distal end 25 IB is larger than the outer diameter of the proximal end 251 A, which results in the angled or tapered orientation of surface 250 and the cone or conical shape of surface 250. The gas distributor 300 has several passageways 362 that exit toward the distal end 25 IB of the conical surface 250 and toward the ridge 252 of the electrode 200.

[0236] Angled or conical surface 250 is oriented at a 10 degree to 20 degree angle relative to the longitudinal axis of the electrode 200. Angled surface 250 is a diverging surface in that it is directed away from the longitudinal axis of the electrode 200 along the direction of the distal end of the electrode. Angled surface 252 is a converging surface in that it is directed back toward the longitudinal axis of the electrode 200 along the direction of the distal end of the electrode 200.

[0237] Turning to FIGS. 63-65, different side views showing the air flow exiting the gas distributor proximate to the electrode surface are illustrated. The electrode 200 and its angled surfaces 250 and 254 and ridge 252 are shown. Gas distributor 300 has several passageways 362, which are shown in phantom, with the gas distributor being transparent for ease of reference. AirAttorney Docket No. 1485.1086i2PATENTflows exiting the passageways 362 is represented by the arrow 390. The orientation of the air flows 390 exiting passageways 362 are at an angle of angle “Z” relative to the longitudinal axis of the electrode 200. In this embodiment, angle “Z’ is between 25 degrees and 45 degrees. In one embodiment, angle “Z” is 30 degrees. The air flows 390 are the air injections of the plasma gas flow along the outer surface of the electrode 200 and into the plasma chamber. In FIG. 64, the letter “X” shows how the air flows 390 are directed toward and close to the distal end 25 IB of the conical surface 250 . The DCM, and in particular, the gas distributor 300 swirls the air exiting the gas distributor 300 at the angle “Z”. The air flows 390 are directed into the plasma chamber in a swirling pattern. By the fluid flow shooting down toward and close to the ridge 252 and the distal end 25 IB of the conical surface 250, heat transfer from the electrode 200 is improved and the overall fluid flow is also improved. The fluid flow shooting down may contact the ridge 252 and only a small portion of surface 250 adjacent to the distal end 25 IB. If the fluid exiting the gas distributor 300 was impinging on a surface in a perpendicularly direction to the surface (such as surface 250), that would result in too much turbulence in the plasma flow.

[0238] The O-rings 270 and 272 that are located in grooves formed in the outer surface of the gas distributor 300 are shown in FIG. 63. As mentioned above, gas distributor 300 has a hole extending therethrough into which the arc initiator 500 is placed. The arc initiator 500 has a proximal end 502 and a distal end 504. The distal end 504 is located proximate to the conical surface 250 and in particular to distal end 25 IB.

[0239] Turning to FIG. 66, a close-up side view of the angled surfaces 250 and 254 and the ridge 252 at the distal end 25 IB of the conical surface 250 is shown. The distal end 504 of the arc initiator 500 is positioned very close to the conical surface 250 and the ridge 252 of electrode 200. During initiation of the torch operation, a voltage is applied between the arc initiator 500 and the electrode 200. Due to such a small gap between the arc initiator 500 and the conical surface of the electrode 200, it is the location at which plasma flow is initiated.

[0240] FIGS. 67 and 68 are cross-sectional side views of a DCM according to the present invention. The gas distributor 300 with the arc initiator 500 is shown positioned between the electrode 200 and the tip or nozzle 400. The gas distributor 300 has an inner surface 342 and an outer surface 330. The electrode 200 has a cylindrical outer surface 246 that is in contact with the inner wall surface 342 of the gas distributor 300. The nozzle 400 has an inner surface 450 that hasAttorney Docket No. 1485.1086i2PATENTan upper part 451 in contact with the outer surface 330 of the gas distributor 300. The gas distributor 300 is press-fit onto the electrode 200, and the gas distributor 300 / electrode 200 combination is press-fit into the nozzle 400. Collectively, the electrode 200, the gas distributor 300, and the nozzle 400 form a DCM. The electrode 200 and the nozzle 400 are formed of a metal material and the gas distributor 300 is formed of a deformable material, such as plastic, that is softer than the electrode 200 and the nozzle 400.

[0241] To assist with maintaining the DCM components together, the electrode 200 physically engages the gas distributor 300 to maintain a positive engagement therewith. Similarly, the nozzle 400 is physically engages the gas distributor 300 to maintain a positive engagement therewith. Turning to FIG. 69, a proximal end view of an embodiment of a DCM according to the present invention is illustrated. The view is taken of the proximal end of the electrode 200, with the gas distributor 300 and the nozzle 400 shown around the electrode 200.

[0242] In one embodiment, the outer surface 246 of the electrode 200 has several spaced apart indentations 290, 292, 294, and 296 that receive a small portion of the gas distributor 300 when the electrode 200 is pressed into and physically engages the gas distributor 300. As a result, not only are the electrode 200 and the gas distributor 300 frictionally engaged with each other, but due to the electrode 200 being made of a stronger material, the gas distributor 300 engages the indentations 290, 292, 294, and 296 of the electrode 200.

[0243] In one embodiment, the nozzle 400 includes similar structures that engage with the outer surface 330 of the gas distributor 300. Referring to FIG. 69, the inner surface part 451 of the nozzle 400 has several spaced apart indentations 490, 492, 494, and 496 that receive small portions of the outer surface 330 of the gas distributor 300 when the gas distributor 300 is pressed into the nozzle 400. The engagement of indentations 490, 492, 494, and 496 and the gas distributor 300 provide for the coupling and retention of the nozzle 400 to the gas distributor 300. In this embodiment, the electrode 200, the gas distributor 300, and the nozzle 400 are intended to be maintained together and not separated, and to be inserted into torch head and removed from the torch head as a collective unit.

[0244] In one alternative embodiment, as different nozzles with different outer profiles are inserted into the shield cup assembly, different sized annular gaps are defined between the nozzleAttorney Docket No. 1485.1086i2PATENTouter profile or surface and the inner surface of the shield assembly. The annular gap is the space through which a shield gas flow travels. Due to the differences in the outer profiles, the sizes of the annular gaps between the nozzles and the shield assembly will vary. When the size of the annular gap decreases from one nozzle to the other nozzle, the flow restriction on the shield gas flow increases and the flow of the shield gas decreases, which will increase the flow of the plasma gas. This aspect is discussed in greater detail below.

[0245] In alternative embodiments, the inner surfaces of each of the distal shield cup member and the proximal shield cup member define an annular gap with the outer surface of the nozzle located in the shield cup assembly. When nozzles with outer surfaces with different outer diameters and profiles are inserted into the shield cup assembly, the size of the annular gap varies. If a smaller annular gap is desired so that the pressure drop in the shield gas flow increases, then a nozzle that has a larger outer diameter or profile is used because the shield cup assembly remains the same. If a larger annular gap is desired so that the pressure drop in the shield gas flow decreases, then a nozzle that has a smaller outer diameter or profile is used in the shield cup assembly. By utilizing different sets of consumables, each of which has a different nozzle, with a constant shield cup assembly, the operation and functionality of the torch head can be adjusted. Namely, the use of different shaped and sized nozzles with a similar shield cup assembly results in different back pressures in the shield gas flow and a different flow for the plasma gas flow.

[0246] While the consumables presented herein have been illustrated and described in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. For example, as mentioned, the consumables presented herein may be modified to connect to or be used with any other desired consumable or non-consumable components, including to facilitate a specific arc initiation technique. Additionally, the consumables presented herein may be suitable for automated (e.g., mechanized) and / or manual (e.g., handheld) cutting.

[0247] In addition, various features from one of the embodiments may be incorporated into another of the embodiments. That is, it is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has beenAttorney Docket No. 1485.1086i2PATENTdisclosed in a preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.

[0248] It is also to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the invention. Additionally, it is also to be understood that the consumables described herein, or portions thereof may be fabricated from any suitable material or combination of materials, such as plastic or metals (e.g., copper, bronze, hafnium, etc.), as well as derivatives thereof, and combinations thereof.

[0249] Finally, when used herein, the term “comprises” and its derivations (such as “comprising”, etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc. Similarly, where any description recites “a” or “a first” element or the equivalent thereof, such disclosure should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Meanwhile, when used herein, the term “approximately” and terms of its family (such as “approximate,” etc.) should be understood as indicating values very near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc.). For example, the term “approximately” may denote a tolerance of plus or minus 0.002 inches, 0.001 inches, or up to 0.005 inches. The same applies to the terms “about” and “around” and “substantially.”

Claims

Attorney Docket No. 1485.1086i2PATENTWhat is claimed is:

1. A set of consumables positionable in a shield cup assembly of a plasma arc torch that receives a flow of fluid from a fluid source, the set of consumables comprising:a nozzle having a cavity;an electrode; anda gas distributor having an opening therethrough, wherein the electrode is inserted into the opening of the gas distributor, the gas distributor is inserted into the cavity of the nozzle, fluid flows from the gas distributor along an outer surface of the electrode, the nozzle physically engages the gas distributor to couple the nozzle and the gas distributor, and the electrode physically engages the gas distributor to couple the electrode and the gas distributor, wherein the nozzle, the gas distributor, and the electrode are retained together as a unit.

2. The set of consumables of claim 1, wherein the gas distributor has a plurality of passageways, each of which is oriented at an angle from 25 degrees to 45 degrees relative to a longitudinal axis of the electrode.

3. The set of consumables of claim 2, wherein the plurality of passageways are oriented at an angle of 30 degrees relative to the longitudinal axis of the electrode.

4. The set of consumables of claim 1, wherein the electrode has an outer surface that includes a conical surface with a proximal end and a distal end, and the fluid flowing from the gas distributor is directed toward and engages the distal end of the conical surface of the electrode.

5. The set of consumables of claim 4, wherein the conical surface is oriented so that its distal end has a larger diameter than its proximal end.Attorney Docket No. 1485.108612PATENT6. The set of consumables of claim 1, wherein the nozzle has a shoulder that has an outer surface, and when the nozzle is placed in the shield cup assembly, an annular gap is formed between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly.

7. The set of consumables of claim 6, wherein a flow of fluid flows into the electrode and is separated into a first flow portion and a second flow portion, the first flow portion travels between the nozzle and the electrode and forms a plasma gas flow, the second flow portion travels between the nozzle and the shield cup assembly and forms a shield gas flow, and the second flow portion flows through the annular gap.

8. The set of consumables of claim 7, wherein a rate of the first flow portion can be adjusted by modifying a configuration of an outlet bore in the nozzle, and a rate of the second flow portion can be adjusted by modifying a width of the annular gap between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly.

9. The set of consumables of claim 1, wherein the nozzle has an outer surface with a knurled pattern of grooves formed therein, and the knurled pattern of grooves provide a gripping surface and an improved cooling function for the outer surface of the nozzle.

10. A set of consumables positionable in a shield cup assembly of a plasma arc torch that receives a flow of fluid from a fluid source, the set of consumables comprising:a nozzle having a cavity;an electrode, the electrode having an outer surface that includes a conical surface with a proximal end and a distal end; anda gas distributor having an opening and a plurality of passageways, the electrode being inserted into the opening of the gas distributor, and the gas distributor being inserted into the cavity of the nozzle, wherein fluid flows from the gas distributor along the outer surface of the electrode in a direction that is directed toward and engages the distal end of the conical surface.Attorney Docket No. 1485.1086i2PATENT11. The set of consumables of claim 10, wherein the nozzle physically engages the gas distributor to couple the nozzle and the gas distributor, and the electrode physically engages the gas distributor to couple the electrode and the gas distributor, wherein the nozzle, the gas distributor, and the electrode are retained together as a unit.

12. The set of consumables of claim 10, wherein the nozzle has a shoulder that has an outer surface, and when the nozzle is placed in the shield cup assembly, an annular gap is formed between the outer surface of the shoulder of the nozzle and an inner wall of the shield cup assembly, and wherein a flow of fluid flows into the electrode and splits into a plasma gas flow and into a shield gas flow, and the shield gas flow travels through the annular gap.

13. The set of consumables of claim 12, wherein the nozzle has an orifice in fluid communication with the cavity of the nozzle, the orifice having an inner diameter, and the inner diameter is in a range of approximately 0.031 inches to approximately 0.060 inches.

14. The set of consumables of claim 12, wherein the outer surface of the shoulder of the nozzle defines an outer diameter, and the outer diameter is in a range of approximately 0.713 inches to approximately 0.720 inches.

15. The set of consumables of claim 14, wherein a distance between the outer surface of the shoulder of the nozzle and the inner wall of the shield cup assembly is in a range of approximately 0.004 inches to approximately 0.011 inches.

16. The set of consumables of claim 10, wherein the electrode is engageable with and remains in contact with a contact band in a torch head when the electrode is moved into the torch head.Attorney Docket No. 1485.1086i2PATENT17. A plasma arc torch that receives a flow of fluid from a fluid source, the flow of fluid being split into a first flow portion that is a plasma flow and a second flow portion that is a shield flow, the plasma arc torch comprising:a shield assembly including a shield cup member having including a plurality of passageways formed therein, the shield cup member having an inner surface;a first set of consumables engageable with a torch head, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, the first nozzle having a first outlet bore with a first configuration, the first nozzle having a first outer shoulder, the first outer shoulder and the inner surface of the shield cup member defining a first annular gap; anda second set of consumables engageable with the torch head, the second set of consumables including a second nozzle, a second electrode, and a second gas distributor, the second nozzle having a second outlet bore with a second configuration, the second configuration being different from the first configuration, the second nozzle having a second outer shoulder, the second outer shoulder and the inner surface of the shield cup member defining a second annular gap, the second annular gap having a different width than the first annular gap, wherein, depending on which of the first set of consumables or the second set of consumables is engaged with the torch head, the first flow portion travels through either the first outlet bore or the second outlet bore, the second flow portion travels through either the first annular gap or the second annular gap, and the first flow portion and the second flow portion can be adjusted by the first outlet bore and the first annular gap or the second outlet bore and the second annular gap.

18. The plasma arc torch of claim 17, wherein a width of the first annular gap is either in a range of approximately 0.047 inches to approximately 0.051 inches or in a range of approximately 0.004 inches to approximately 0.011 inches.

19. The plasma arc torch of claim 18, wherein the first outer shoulder of the first nozzle defines an outer diameter, and the outer diameter is either in a range of approximately 0.673 inches to approximately 0.677 inches or in a range of approximately 0.713 inches to approximately 0.720 inches.Attorney Docket No. 1485.1086i2PATENT20. The plasma arc torch of claim 17, wherein the first electrode has an outer surface that includes a conical surface with a proximal end and a distal end, and fluid flowing from the first gas distributor is directed toward and engages the distal end of the conical surface of the first electrode.

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