Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes

1. An electrode for a contact start plasma arc torch in electrical communication with a power supply, the electrode being movable relative to a nozzle within a plasma chamber of the torch, the electrode comprising:

an elongated electrode body formed of an electrically conductive material, the electrode body defining a longitudinal axis; and

a resilient element contacting a proximal end of the electrode body and imparting a separation force to the electrode body, wherein the electrode body is adapted to overcome the separation force and engage a contact element of the torch when the torch is operated in a transferred arc mode.

2. The electrode of claim 1 , wherein the electrode body further comprises a reaction surface disposed in a spaced relationship relative to the proximal end of the electrode body, wherein the reaction surface is configured for electrical communication with the resilient element.

3. The electrode of claim 2 , wherein the reaction surface comprises a radially extending flange formed integrally with the electrode body.

4. The electrode of claim 1 , wherein the resilient element is secured relative to the proximal end of the electrode body.

5. The electrode of claim 1 , wherein the resilient element is secured by a diametral interference fit.

6. The electrode of claim 1 , wherein the resilient element is formed integrally with the electrode body.

7. The electrode of claim 1 , further comprising a hollow body for maintaining the resilient element and slideably receiving the electrode body.

8. The electrode of claim 7 , wherein the hollow body is a swirl ring.

9. The electrode of claim 1 , wherein the contact element includes a first surface and a second surface, the first surface facilitating electrical communication with the power supply and the second surface is characterized by physical contact with the electrode body when the torch is operated in the transferred arc mode.

10. The electrode of claim 9 , wherein the second surface of the contact element is characterized by absence of physical contact with the electrode body during initiation of a pilot arc.

11. The electrode of claim 9 , wherein the contact element further comprises a connective member extending from the second surface to slideably engage the electrode body.

12. The electrode of claim 11 , wherein the connective member is formed integrally with the second surface.

13. The electrode of claim 11 , wherein the contact element further comprises an aligning portion defining an axis, the aligning portion disposed in a spaced relationship with the proximal end of the electrode body and configured to restrain radial movement of the electrode body.

14. The electrode of claim 11 , wherein a portion of the contact element facilitates passage of a pilot arc current between the contact element and the electrode body when the contact element slideably engages the electrode body.

15. The electrode of claim 1 , wherein the resilient element passes at least substantially all of a pilot arc current between the power supply and the electrode body.

16. The electrode of claim 1 , wherein the resilient element is not electrically conductive.

17. The electrode of claim 16 , further comprising a conductive element for passing at least substantially all of a pilot arc current between the power supply and the electrode body.

18. An electrode for a contact start plasma arc torch in electrical communication with a power supply, the electrode being movable relative to a nozzle within a plasma chamber of the torch, the electrode comprising:

an elongated electrode body formed of an electrically conductive material and defining a longitudinal axis, the electrode body comprising:

a first surface characterized by i) physical contact with a contact element when the torch is operated in a transferred arc mode and ii) absence of physical contact with the contact element during initiation of a pilot arc; and

a second surface positioned remotely from the first surface, the second surface contacting a resilient element configured to impart a separation force between the electrode body and the contact element.

19. The electrode of claim 18 , wherein the contact element comprises an annular configuration.

20. The electrode of claim 18 , further comprising a receptacle disposed within the proximal end of the electrode body for receiving at least a portion of the contact element such that a first portion of the contact element is physically remote from the electrode body during initiation of a pilot arc, the first portion for passing at least substantially all of a transferred arc current between the power supply and the electrode body at the first surface when the torch is operated in the transferred arc mode.

21. The electrode of claim 20 , wherein the receptacle further comprises:

a cylindrical portion; and

a restraint surface disposed at a proximal end of the receptacle for reacting against a portion of the contact element to hinder disengagement of the contact element from the receptacle.

22. The electrode of claim 21 , wherein the restraint surface comprises an annular configuration.

23. The electrode of claim 21 , wherein the cylindrical portion is defined by a first diameter, the restraint surface comprises a second diameter, and a distal region of a connective member of the contact element defines a third diameter, such that the third diameter is greater than the second diameter and less than the first diameter.

24. The electrode of claim 23 , wherein the distal region is a distal end of the connective member.

25. The electrode of claim 20 , wherein the resilient element is retained by the electrode body.

26. The electrode of claim 25 , wherein the resilient element is retained by a diametral interference fit.

27. The electrode of claim 25 , wherein the resilient element is disposed within the receptacle.

28. The electrode of claim 18 , wherein the second surface comprises a radially extending flange formed integrally with the electrode body.

29. A contact start plasma arc torch comprising:

a power supply for providing current to the torch;

a plasma chamber defined by a nozzle and an electrically conductive electrode body slideably mounted within the torch and defining a longitudinal axis;

a power contact disposed in a stationary position relative to the plasma chamber, the power contact in electrical communication with the power supply; and

a resilient element contacting a proximal end of the electrode body and imparting a separation force to the electrode body, wherein the electrode body is adapted to overcome the separation force and engage the power contact when the torch is operated in a transferred arc mode.

30. The plasma arc torch of claim 29 , further comprising a swirl ring that imparts radial motion to a gas flowing through the torch.

31. The plasma arc torch of claim 29 , further comprising a shield defining an exit port positioned adjacent an exit orifice of the nozzle, the shield mounted on a retaining cap supported on a torch body of the plasma arc torch.

32. The plasma arc torch of claim 29 , wherein the power contact passes at least substantially all of a transferred arc current between the power supply and the electrode body when the torch is operated in the transferred arc mode.

33. The plasma arc torch of claim 29 , wherein the resilient element passes at least substantially all of a pilot arc current between the power supply and the electrode body when the torch is operated in a pilot arc mode.

34. The plasma arc torch of claim 29 , further comprising a conductive element for passing at least substantially all of a pilot arc current between the power supply and the electrode body when the torch is operated in a pilot arc mode, wherein the resilient element is not electrically conductive.