Plasma Nozzle with Segmented Channels for Arc Control
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Solution Overview
Problem
Existing plasma nozzles have limited plasma flow efficiency due to restricted energy transfer within the nozzle channel, leading to reduced effectiveness and potential surface damage from high-temperature arcs, and require separate high-voltage transformers for parallel connections, increasing equipment costs and safety risks.
Innovation Solution
A plasma nozzle design featuring multiple separate nozzle channels that combine into a single outlet, preventing arc contact with the nozzle walls and using a high-frequency alternating voltage to ignite and maintain the arc, ensuring efficient plasma flow and surface treatment without surface damage or electrical hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nozzle channel is enlarged to increase process gas flow rate, then the flow rate of process gas is increased, but the energy transfer from arc to process gas is limited and most gas flows along the wall with low energy transfer
Solution Approach 1:
The single nozzle channel is divided into multiple separate nozzle channels (at least two), each with its own arc discharge path. This segmentation allows each channel to maintain efficient energy transfer while the total flow rate increases with the number of channels.
2Productivity
If separate high-voltage transformers are provided for each nozzle in parallel arrangement, then plasma flow is increased, but the equipment expenditure and device complexity increases considerably
Solution Approach 1:
Multiple nozzle channels are electrically connected in series between single high-voltage transformer, allowing one transformer to power all channels. The series connection enables synchronized ignition and eliminates the need for multiple transformers, reducing equipment complexity and cost.
3Power
If arc runs between pin electrode and ring electrode, then plasma is generated, but the arc is unstable, splits at nozzle opening, and high temperature damages the surface to be treated
Solution Approach 1:
The arc discharge is extracted away from the nozzle outlet by positioning electrodes such that the arc runs along the inner wall of the nozzle channel rather than at the opening. This separates the high-temperature arc zone from the treatment zone, preventing surface damage while maintaining plasma generation.
4Duration of action of stationary object
If arc runs along nozzle channel wall, then service life is increased, but arc deposition occurs inside the nozzle channels
Solution Approach 1:
The nozzle channel is designed with different material properties or surface treatments in different zones: the upper portion where arc runs has arc-resistant properties to extend service life, while the lower portion has easy-clean properties to prevent deposition accumulation and facilitate maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances plasma flow efficiency, increases the service life of the nozzle by preventing arc deposition, and allows for synchronous ignition of multiple nozzles with a single transformer, ensuring safer and more effective surface treatment.
Implementation Method 1
an arc is ignited by a high-frequency alternating voltage
Implementation Method 2
high-frequency alternating voltage to ignite and maintain the arc
Implementation Method 3
the arc...creates a partially ionized reactive gas with a lower temperature than in the arc plasma
Implementation Method 4
the arc inside the nozzle channel to the process gas flow is limited
Data Source
Figure 1
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AI summary
The invention relates to a plasma die and to a method for the treatment of surfaces of work pieces with plasma dies, comprising a housing (1), which has a first electrode unit (3) with which a first die channel (15) is associated, wherein the first die channel (15) has at least one electrically conductive wall and is insulated from the first electrode unit, and said housing accommodating at least one additional electrode unit (3'), having means for applying a voltage between the first and second electrode units (3, 3') and additionally having means (11) for supplying a process gas flow to each electrode unit (3, 3'), wherein a separate die channel (15) is associated with the at least one additional electrode unit (3'), said die channel having an electrically conductive wall that is insulated from the associated electrode unit (3'), said separate die channels (15) being disposed such that the process gas flows unite and form in a common die exit opening (16) of a die tip (14), and the walls of the first and second die channels (15) are directly electrically connected to one another.