Swirl ring for a plasma arc torch

1. A swirl ring for a plasma arc torch, the swirl ring comprising:

a hollow body having a distal end and a proximal end and configured to receive at least a portion of an electrode within the hollow body, the proximal end configured to attach to a torch body of the plasma arc torch and the distal end configured to attach to a nozzle of the plasma arc torch, the hollow body defining a longitudinal axis extending from the proximal end to the distal end;

a first set of flange segments circumferentially disposed on an interior surface of the hollow body, the first set of flange segments extending radially inward from the interior surface and shaped to retain a first surface of a sealing member; and

a second set of flange segments circumferentially disposed on the interior surface of the hollow body, the second set of flange segments extending radially inward from the interior surface and shaped to retain a second surface of the sealing member,

wherein (i) the second set of flange segments are spaced distally from the first set of flange segments along the longitudinal axis, and (ii) flange segments of the second set of flange segments are radially offset from flange segments of the first set of flange segments.

2. The swirl ring of claim 1 , wherein the hollow body, the first set of flange segments and the second set of flange segments are injection molded.

3. The swirl ring of claim 2 , wherein the hollow body, the first set of flange segments and the second set of flange segments are molded from a stable polymer comprising silicone or fluoropolymer.

4. The swirl ring of claim 2 , wherein at least one flange segment in the first set of flange segments comprises a protrusion or indent for injection molding marking.

5. The swirl ring of claim 1 , wherein the sealing member is an O-ring.

6. The swirl ring of claim 5 , wherein a distal spacing between the first and second sets of flange segments corresponds to a width of the sealing member.

7. The swirl ring of claim 1 , wherein the first set of flange segments and the second set of flange segments are located radially in an alternating fashion about the longitudinal axis.

8. The swirl ring of claim 1 , wherein the first set of flange segments and the second set of flange segments do not radially or axially overlap.

9. The swirl ring of claim 1 , wherein the radial offset between the flange segments of the first and second sets of flange segments comprises the flange segments of the first set of flange segments not overlapping with the flange segments of the second set of flange segments when viewed from at least one of the proximal end or the distal end of the hollow body.

10. The swirl ring of claim 1 , wherein the first set of flange segments comprises four distinct flange segments.

11. The swirl ring of claim 1 , wherein the second set of flange segments comprises four distinct flange segments.

12. The swirl ring of claim 1 , wherein the distal end includes one or more recessed regions.

13. The swirl ring of claim 1 , wherein a cross-section of the swirl ring that is perpendicular to the longitudinal axis is oblong in shape.

14. A swirl ring for a plasma arc torch prepared by a process comprising:

injection molding a stable polymer material to form a hollow body having a distal end and a proximal end and defining a longitudinal axis extending from the proximal end to the distal end;

injection molding the stable polymer material to form a first set of flange segments circumferentially disposed on an interior surface of the hollow body, the first set of flange segments extending radially inward from the interior surface and shaped to retain a first surface of a sealing member; and

injection molding the stable polymer material to form a second set of flange segments circumferentially disposed on the interior surface of the hollow body, the second set of flange segments extending radially inward from the interior surface and shaped to retain a second surface of the sealing member,

wherein (i) the second set of injection molded flange segments are spaced distally from the first set of injection molded flange segments along the longitudinal axis, and (ii) flange segments of the second set of injection molded flange segments are radially offset from flange segments of the first set of injection molded flange segments.

15. The swirl ring of claim 14 , wherein the injection molding of the hollow body, the first set of flange segments and the second set of flange segments occur simultaneously.

16. The swirl ring of claim 14 , wherein the stable polymer material comprises at least one of silicone or a fluoropolymer.

17. The swirl ring of claim 16 , wherein the fluoropolymer is fluorinated ethylene propylene (FEP).

18. The swirl ring of claim 14 , wherein the sealing member is an O-ring.

19. The swirl ring of claim 14 , wherein the radial offset between the flange segments of the first and second sets of injection molded flange segments comprises the flange segments of the first set of injection molded flange segments not overlapping with the the flange segments of the second set of injection molded flange segments when viewed from at least one of the proximal end or the distal end of the hollow body.

20. The swirl ring of claim 14 , wherein the first set of injection molded flange segments comprises at least four distinct flange segments.

21. The swirl ring of claim 14 , wherein the second set of injection molded flange segments comprises at least four distinct flange segments.