Diffuser shape vent slots in a hand torch shield castellation

1. A torch tip for a plasma arc torch for reducing molten spatter buildup during operation of the plasma arc torch, the torch tip comprising:

a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch;

an end wall disposed at the second end of the body;

a plasma exit orifice formed in the end wall at the second end of the body;

at least two castellations formed in the end wall; and

at least one slot disposed between two castellations, the at least one slot defined by a first castellation wall, a second castellation wall opposite the first castellation wall, and a slot floor, the torch tip having at least one of the following characteristics:

(a) a slope of the slot floor within the at least one slot tapers in an outward radial direction relative to the plasma exit orifice toward the first end of the body, or

(b) a distance between the first and second castellation walls along the slot floor increases with distance away from the plasma exit orifice.

2. The torch tip of claim 1 wherein the torch tip includes three slots.

3. The torch tip of claim 1 wherein the torch tip is a shield.

4. The torch tip of claim 1 wherein the first castellation wall and the second castellation wall are angled from about 45 arc degrees to about 75 arc degrees about the end wall.

5. The torch tip of claim 1 wherein the at least one slot has a rounded, generally semi-cylindrical, or generally semi-frustoconical geometry.

6. The torch tip of claim 1 wherein the torch tip is made from a material having a high thermal conductivity.

7. The torch tip of claim 6 wherein the torch tip is formed of copper.

8. The torch tip of claim 1 wherein the torch tip includes three slots and three castellations separating each of the slots.

9. The torch tip of claim 8 wherein each castellation has a substantially planar top surface.

10. The torch tip of claim 1 wherein the height of the first and second castellation walls increases with distance from the exit orifice.

11. A shield for a plasma arc torch comprising:

a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch;

an end wall disposed at the second end of the body;

a plasma exit orifice formed in the end wall at the second end of the body;

at least two castellations formed in the end wall; and

no more than three slots disposed between the at least two castellations, each slot having a generally semi-frustoconical geometry and defined by a first castellation wall, a second castellation wall opposite the first castellation wall, and a slot floor, wherein the shield has at least one of the following characteristics:

(a) a slope of the slot floor within the at least one slot tapers in an outward radial direction relative to the plasma exit orifice toward the first end of the body, or

(b) a distance between the first and second castellation walls along the slot floor increases with distance away from the plasma exit orifice.

12. The shield of claim 11 wherein the shield includes three castellations and three slots disposed between the castellations.

13. The shield of claim 11 wherein the first castellation wall and the second castellation wall are angled from about 45 arc degrees to about 75 arc degrees about the end wall.

14. A torch tip for a plasma arc torch for reducing molten spatter buildup during operation of the plasma arc torch, the torch tip comprising:

a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch;

an end wall disposed at the second end of the body;

a plasma exit orifice formed in the end wall at the second end of the body;

three castellations formed in the end wall; and

three slots disposed between the castellations, each slot defined by a first castellation wall, a second castellation wall opposite the first castellation wall, and a slot floor, wherein the torch tip has at least one of the following characteristics:

(a) a slope of the slot floor within the at least one slot tapers in an outward radial direction relative to the plasma exit orifice toward the first end of the body, or

(b) a distance between the first and second castellation walls along the slot floor increases with distance away from the plasma exit orifice.

15. The torch tip of claim 14 wherein the torch tip is a shield.

16. The torch tip of claim 14 wherein the slots extend radially from the plasma exit orifice.

17. A plasma arc torch system comprising:

a torch body defining a plasma gas flow path for directing a plasma gas to a plasma chamber in which a plasma arc is formed;

an electrode disposed within the torch body;

a nozzle disposed relative to the electrode at a distal end of the torch body to define the plasma chamber; and

a shield disposed relative to an exterior surface of the nozzle at the distal end of the torch body, the shield comprising:

a shield body having a first end configured to attach to the torch body and a second end;

an end wall disposed at the second end of the body;

a plasma exit orifice formed in the end wall at the second end of the shield body;

at least two castellations formed in the end wall; and

at least one slot disposed between two castellations, the at least one slot being defined by a first castellation wall, a second castellation wall opposite the first castellation wall, and a slot floor, the shield having at least one of the following characteristics:

(a) a slope of the slot floor within the at least one slot tapers in an outward radial direction relative to the plasma exit orifice toward the first end of the body, or

(b) a distance between the first and second castellation walls along the slot floor increases with distance away from the plasma exit orifice.