IP Library › Granted Patent US 12,275,082
Granted Patent B2
US 12,275,082 · App. 18/203,981 · Granted Apr 15, 2025

Consumable cartridge for a plasma arc cutting system

Inventors: Nicholas A. Sanders (Enfield, NH); Peter J. Twarog (Meriden, NH); E. Michael Shipulski (Etna, NH); Yu Zhang (Hanover, NH)
Assignee: Hypertherm, Inc.
B23K10/006B23K10/00H05H1/34H05H1/3457H05H1/3489H05H1/3494
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Quick Facts
Patent No.
US 12,275,082
App. No.
18/203,981
Granted
Apr 15, 2025
Kind
B2
Abstract

The invention features a replaceable cartridge for a plasma arc torch. The cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

Claims (32)

1. A replaceable sealed cartridge member for a plasma arc torch, the replaceable sealed cartridge member comprising:

a substantially hollow frame including a first substantially hollow portion having a first end and a second substantially hollow portion having a second end, the first and second ends defining a longitudinal axis therethrough, the first end of the substantially hollow frame configured to mate with the plasma arc torch;

an arc emitter slidably positioned and disposed at least partially within the frame, the arc emitter translatable relative to the frame;

a swirl ring extending along at least a portion of a length of the arc emitter in a direction of the longitudinal axis, an unreleasable interface between the hollow frame and the swirl ring, the unreleasable interface joining components as part of the replaceable sealed cartridge; and

an electrically conductive contact element at the first end of the frame, a resilient element located between the arc emitter and the electrically conductive contact element;

wherein the replaceable sealed cartridge member is configured to be replaced as a unit after it reaches the end of the life of any constituent component of the replaceable sealed cartridge member.

2. The replaceable sealed cartridge member of claim 1 wherein the unreleasable interface is a press-fit interface.

3. The replaceable sealed cartridge member of claim 1 wherein the unreleasable interface is a snap-fit interface.

4. The replaceable sealed cartridge member of claim 1 wherein the first and second substantially hollow portions are joined at an interface to form the substantially hollow frame, the interface providing a coupling force that secures the first and second substantially hollow portions together.

5. The replaceable sealed cartridge member of claim 1 wherein at least a portion of the arc emitter and the resilient element are irremovably disposed within the substantially hollow frame.

6. The replaceable sealed cartridge member of claim 1 wherein the replaceable sealed cartridge member has a region with a thermal conductivity of between about 200-400 Watts per meter per degree Kelvin.

7. The replaceable sealed cartridge member of claim 1 further comprising a cap insert connected to the second substantially hollow portion of the replaceable sealed cartridge member, the cap insert substantially orienting the arc emitter and retaining the arc emitter within the substantially hollow frame.

8. The replaceable sealed cartridge member of claim 1 wherein the substantially hollow frame includes an electrical insulator.

9. The replaceable sealed cartridge member of claim 1 wherein the substantially hollow frame includes at least one of a metal or a strongly thermally conductive material.

10. The replaceable sealed cartridge member of claim 1 further including at least one set of flow holes, each flow hole in the set of flow holes radially offset from the other flow holes.

11. The replaceable sealed cartridge member of claim 1 wherein the arc emitter includes an electrode and the resilient element includes a spring.

12. The replaceable sealed cartridge member of claim 1 further comprising a nozzle joined to the swirl ring with a snap-fit interface formed between the nozzle and the swirl ring, thereby joining the nozzle with the swirl ring together as part of the cartridge.

13. A replaceable, unitary consumable assembly for a plasma arc torch, the consumable assembly comprising:

a cartridge body having a first section and a second section, the first and second sections forming a substantially hollow chamber;

an electrode included at least partially within the substantially hollow chamber and translatable relative to the cartridge body along a longitudinal axis defined between ends of the cartridge body;

a swirl ring extending along at least a portion of a length of the electrode in a direction of the longitudinal axis, an unreleasable interface between the cartridge body and the swirl ring; and

an electrically conductive contact element retained at least partially within the first section of the cartridge body, the contact start spring element located between the electrode and the electrically conductive contact element,

wherein the replaceable, unitary consumable assembly is configured to be replaced as a unit after it reaches the end of the life of any constituent component of the replaceable, unitary consumable assembly.

14. The replaceable, unitary consumable assembly of claim 13 wherein the unreleasable interface is a press-fit interface.

15. The replaceable, unitary consumable assembly of claim 13 wherein the unreleasable interface is a snap-fit interface.

16. The replaceable, unitary consumable assembly of claim 13 wherein at least a portion of the electrode and the contact start spring element are irremovably disposed within the substantially hollow chamber.

17. The replaceable, unitary consumable assembly of claim 13 wherein the consumable assembly has a region with a thermal conductivity of between about 200-400 Watts per meter per degree Kelvin.

18. The replaceable, unitary consumable assembly of claim 13 further comprising a cap insert connected to the second section of the cartridge body, the cap insert substantially orienting the electrode and retaining the electrode within the cartridge body.

19. The replaceable, unitary consumable assembly of claim 13 wherein the cartridge body includes an electrical insulator.

20. The replaceable, unitary consumable assembly of claim 13 wherein the cartridge body includes at least one of a metal or a strongly thermally conductive material.

21. The replaceable, unitary consumable assembly of claim 13 further including at least one set of flow holes, each flow hole in the set of flow holes radially offset from the other flow holes.

22. The replaceable, unitary consumable assembly of claim 13 further comprising a nozzle joined to the swirl ring with a snap-fit interface formed between the nozzle and the swirl ring, thereby joining the nozzle with the swirl ring together as part of the assembly.

Assignments (2)
SECURITY INTEREST Recorded Dec 13, 2024
From: HYPERTHERM, INC.
To: BANK OF AMERICA, N.A.
Reel/Frame 069577/0777 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 19, 2024
From: SANDERS, NICHOLAS A.; TWAROG, PETER J.; SHIPULSKI, E. MICHAEL; ZHANG, YU
To: HYPERTHERM, INC.
Reel/Frame 066817/0753 →
Continuity (10)
Continuation 17164106 · Feb 1, 2021
Continuation 15971703 · May 4, 2018
Continuation In Part 14824946 · Aug 12, 2015
Continuation In Part 14708972 · May 11, 2015
Continuation In Part 14708957 · May 11, 2015
Continuation In Part PCTUS2014056546 · Sep 19, 2014
Continuation In Part 14079163 · Nov 13, 2013
Provisional Application 62036393 · Aug 12, 2014
Provisional Application 61991114 · May 9, 2014
Related Publication 20240109147A1 · Apr 4, 2024
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