IP Library › Granted Patent US 12,280,441
Granted Patent B2
US 12,280,441 · App. 17/146,090 · Granted Apr 22, 2025

Swirl ring and contact element for a plasma arc torch cartridge

Inventors: Yu Zhang (Hanover, NH); Jesse A. Roberts (Cornish, NH); Zheng Duan (Hanover, NH); Michael Scheller (Grantham, NH); David Agan (Enfield, NH); Steven Moody (Charlestown, NH); Stephen T. Eickhoff (Hanover, NH); Garrett K. Quillia (Enfield, NH)
Assignee: Hypertherm, Inc.
B23K10/02H05H1/34H05H1/3468H05H1/3473H05H1/3489
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Quick Facts
Patent No.
US 12,280,441
App. No.
17/146,090
Granted
Apr 22, 2025
Kind
B2
Abstract

A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Claims (31)

1. A consumable cartridge for a plasma arc torch, the consumable cartridge comprising:

a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features, the discrete retaining features defining at least one protuberance, the at least one protuberance including at least one interior guide track; and

an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features, the contact element having a core, a proximal surface, and a distal surface,

wherein the contact element is disposed at least partially between a torch plunger of the plasma arc torch and an electrode of the plasma arc torch upon installation into the plasma arc torch, and

wherein at least one discrete retaining feature in the plurality of discrete retaining features is configured to engage a switch for sensing a presence of the cartridge frame or the consumable cartridge secured to a torch body of the plasma arc torch.

2. The consumable cartridge of claim 1 wherein the contact element is configured to translate toward (i) a proximal end of the torch plunger of the plasma arc torch upon installation into the plasma arc torch, and (ii) the electrode of the plasma arc torch during an operation of the plasma arc torch.

3. The consumable cartridge of claim 1 wherein the contact element matingly engages the at least one guide track of the protuberance and is freely translatable up to a predetermined distance within the plurality of discrete retaining features of the cartridge frame along the longitudinal axis at the second end.

4. The consumable cartridge of claim 1 wherein the at least one protuberance is a projection or distension configured to enable an operation of the plasma arc torch.

5. The consumable cartridge of claim 1 wherein the at least one protuberance has a linear width of between approximately 1 and 3 millimeters.

6. The consumable cartridge of claim 1 wherein the contact element includes at least one guide channel for interfacing with at least one discrete retaining feature in the plurality of discrete retaining features.

7. The consumable cartridge of claim 1 wherein the plurality of discrete retaining features includes one or more axial stops.

8. The consumable cartridge of claim 1 wherein the cartridge frame forms a swirl ring or swirl feature of the plasma arc torch, the first end of the cartridge frame including a set of passages fluidly connecting an internal surface of the cartridge frame and an external surface of the cartridge frame.

9. The consumable cartridge of claim 1 wherein the contact element includes a snap fit feature for coupling to the cartridge frame.

10. The consumable cartridge of claim 1 further including an electrode disposed within the cartridge frame, the electrode interacting with a spring configured to bias the contact element toward a cathode of the plasma arc torch.

11. The consumable cartridge of claim 1 wherein the contact element is configured to slide along the longitudinal axis during installation in the plasma arc torch upon contact with the torch plunger.

12. The consumable cartridge of claim 1 wherein the plurality of discrete retaining features is shaped to matingly engage the contact element and to define a translation path of the contact element within the cartridge frame.

13. The consumable cartridge of claim 12 wherein the plurality of discrete retaining features and the contact element define a set of vent passages.

14. The consumable cartridge of claim 12 wherein the translation path has two or more radial interface surfaces between the contact element and the cartridge frame.

15. The consumable cartridge of claim 1 wherein the contact element includes scalloped edges.

16. The consumable cartridge of claim 1 wherein the contact element includes a cap feature integrally formed with the core.

17. The consumable cartridge of claim 1 wherein the cartridge frame is formed of a thermoplastic.

18. The consumable cartridge of claim 1 wherein the cartridge frame is molded.

19. The consumable cartridge of claim 1 wherein the contact element is physically separate from an electrode within the consumable cartridge.

20. The consumable cartridge of claim 1 wherein the contact element is removed from direct physical contact with the electrode when the plasma arc torch is not in operation.

21. The consumable cartridge of claim 1 wherein a thickness between the proximal surface and the distal surface is at least double a thickness at a perimeter of the core.

22. The consumable cartridge of claim 1 wherein the contact element has a solid core.

23. A method of operation of a plasma arc torch, the method comprising:

installing a consumable cartridge in the plasma arc torch, the consumable cartridge having a cartridge frame with a first end and a second end that define a longitudinal axis, the consumable cartridge including (i) a protuberance configured to engage a switch for sensing a presence of a consumable component of the plasma arc torch, the protuberance activating the switch when the cartridge is installed in the plasma arc torch, and (ii) an electrically conductive contact element confined by the cartridge frame within a set of guide tracks and freely translatable up to a predetermined distance within the set of guide tracks;

translating the contact element in a first direction along the longitudinal axis toward the first end once contact is made with a torch plunger of the plasma arc torch; and

translating an electrode of the plasma arc torch in a second direction opposite the first direction along the longitudinal axis, the electrode contacting the contact element during a plasma operation of the plasma arc torch;

wherein the contact element is separated from the electrode when the plasma arc torch is not performing the plasma operation.

Assignments (6)
CORRECTIVE ASSIGNMENT TO CORRECT THE COLLATERAL AGENT/ASSIGNEE'S ADDRESS PREVIOUSLY RECORDED AT REEL: 058573 FRAME: 0832. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY INTEREST. Recorded Feb 8, 2022
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 058983/0459 →
SECURITY INTEREST Recorded Jan 5, 2022
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 058573/0832 →
SECURITY INTEREST Recorded Jan 5, 2022
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 058982/0425 →
SECURITY INTEREST Recorded Jan 5, 2022
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 058982/0480 →
SECURITY INTEREST Recorded Dec 30, 2021
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 058510/0810 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 5, 2021
From: ZHANG, YU; ROBERTS, JESSE A.; DUAN, ZHENG; SCHELLER, MICHAEL; AGAN, DAVID; MOODY, STEVEN; EICKHOFF, STEPHEN T.; QUILLIA, GARRETT K.
To: HYPERTHERM, INC.
Reel/Frame 056143/0771 →
Continuity (3)
Continuation 15892687 · Feb 9, 2018
Provisional Application 62456813 · Feb 9, 2017
Related Publication 20210136905A1 · May 6, 2021
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