Plasma Torch Electrode with Improved Cooling Capability

1 . An electrode for a plasma arc torch, the electrode comprising:

a hollow elongated body having an open end and a closed end;

an end face located at the closed end inside of the hollow elongated body, the end face having a center portion; and

a plurality of heat exchanging elements in thermal communication with the end face, the heat exchanging elements having side walls defining an elongated channel between adjacent heat exchanging elements, the elongated channel extending radially from the center portion to an inner surface of the elongated body, the elongated channel providing a thermally conductive path that transfers sufficient heat from the elongated body to a cooling fluid during an operation of the plasma arc torch to prevent premature failure of the electrode.

2 . The electrode of claim 1 , further comprising a cooling post formed of a thermally conductive material disposed at the center portion of the end face, the elongated channel extending from a surface of the cooling post to the inner surface of the elongated body.

3 . The electrode of claim 1 , further comprising at least two extended heat exchanging elements in thermal communication with the inner surface of the elongated body.

4 . The electrode of claim 3 , wherein the at least two extended heat exchanging elements in thermal communication with the inner surface of the elongated body define an elongated groove between adjacent extended heat exchanging elements, the elongated groove extending from the closed end toward the open end of the hollow elongated body.

5 . The electrode of claim 3 , wherein the elongated body is dimensioned to receive a cooling tube that (a) aligns axially with the plurality of heat exchanging elements located inside the closed end in thermal communication with the end face and (b) aligns radially with the at least two extended heat exchanging elements in thermal communication with the inner surface of the elongated body.

6 . The electrode of claim 3 , wherein the at least two extended heat exchanging elements in thermal communication with the inner surface of the elongated body are formed by an extrusion process.

7 . The electrode of claim 3 wherein the at least two extended heat exchanging elements in thermal communication with the inner surface of the elongated body are formed by a stamping process.

8 . The electrode of claim 1 , wherein the elongated channel is curved.

9 . The electrode of claim 1 , wherein the elongated channel is canted.

10 . The electrode of claim 4 , wherein the elongated groove is curved.

11 . The electrode of claim 4 wherein the elongated groove forms a spiral groove along the inner surface of the elongated body.

12 . The electrode of claim 4 wherein the elongated channel extends substantially continuously to the elongated groove.

13 . The electrode of claim 1 wherein the elongated channel extends in a transverse direction relative to a longitudinal axis extending through the open and the closed ends of the elongated body of the electrode.

14 . An electrode for a plasma arc torch, the electrode comprising:

a hollow elongated body having an open end, a closed end and an inner surface;

an end face located at the closed end inside of the hollow elongated body, the end face having a central region; and

at least two extended heat exchanging elements in direct thermal communication with the inner surface of the elongated body, the extended heat exchanging elements having side walls defining an elongated groove between adjacent extended heat exchanging elements, the elongated groove extending axially from the closed end to the open end.

15 . The electrode of claim 14 , wherein the extended heat exchanging elements and the elongated groove extend radially along the end face, the heat exchanging elements in direct thermal communication with the inner surface and the end face of the elongated body.

16 . The electrode of claim 14 , wherein the elongated groove provides a thermally conductive path that transfers sufficient heat from the elongated body to a cooling fluid during an operation of the plasma arc torch to prevent premature failure of the electrode.

17 . The electrode of claim 14 wherein the at least two extended heat exchanging elements are formed by a stamping process.

18 . A plasma arc torch system comprising:

an electrode disposed within a torch body, the electrode comprising

a hollow elongated body having an open end and a closed end;

an end face located at the closed end inside of the hollow elongated body, the end face having a center portion; and

a plurality of heat exchanging elements in thermal communication with the end face, the heat exchanging elements having side walls defining an elongated channel between adjacent heat exchanging elements, the elongated channel extending radially from the center portion to an inner surface of the elongated body, the elongated channel providing a thermally conductive path that transfers sufficient heat from the elongated body to a cooling fluid during an operation of the plasma arc torch to prevent premature failure of the electrode; and

a cooling tube disposed at least partially within the hollow elongated electrode body, the cooling tube comprising an elongated body having a coolant passage extending therethrough, wherein the cooling tube is aligned radially with the at least two heat exchanging elements of the electrode.

19 . The plasma arc torch system of claim 18 further comprising a nozzle disposed relative to the electrode at a distal end of the torch body to define a plasma chamber.

20 . The plasma arc torch system of claim 19 further comprising a shield disposed relative to an exterior surface of the nozzle at a distal end of the torch body.