Patents Assigned to Hypertherm, Inc.
  • Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes
    Patent number: 8546718
    Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material. The electrode body is movable relative to the torch. A resilient element, contacting a proximal end of the electrode body, is used for imparting a separation force to the electrode body. 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.
    Type: Grant
    Filed: December 20, 2011
    Date of Patent: October 1, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Stephen T. Eickhoff, Jesse Roberts
  • Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes
    Patent number: 8541712
    Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material. The electrode body is movable relative to the torch. The electrode and torch can include a contact element having a first surface in electrical communication with the power contact and a second surface characterized by (i) physical contact with the electrode body during transferred arc mode and (ii) absence of physical contact with the electrode body during initiation of a pilot arc.
    Type: Grant
    Filed: December 20, 2011
    Date of Patent: September 24, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Stephen T. Eickhoff, Jesse Roberts
  • Method and apparatus for automatic gas control for a plasma arc torch
    Patent number: 8541710
    Abstract: A method and apparatus for controlling a gas supply to a plasma arc torch uses a proportional control solenoid valve positioned adjacent the torch to manipulate the gas flow to the torch, thereby extending electrode life during arc transfer and shutdown. Swirl ring design can be simplified and gas supply and distribution systems become less complicated. The invention also allows manipulation of shield gas flow to reduce divot formation when making interior cuts. The system can be controlled with a digital signal processor utilizing a feedback loop from a sensor.
    Type: Grant
    Filed: February 29, 2008
    Date of Patent: September 24, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Aaron D. Brandt, Christopher S. Passage, Shane M. Selmer, Girish R. Kamath, Guy T. Best, Stephen M. Liebold, Jon W. Lindsay, Zheng Duan
  • Internal part feature cutting method and apparatus
    Patent number: 8541711
    Abstract: A method for cutting an internal feature in a workpiece using a plasma cutting system can include cutting in a first zone using at least one cutting parameter from a first cutting parameter set, which can include a first cutting current and/or a first speed. The method can include cutting in a second zone using at least one cutting parameter from a second cutting parameter set that can be different from the first cutting parameter set. The second cutting parameter set can include a second cutting current and/or a second speed. The method can also include cutting in a third zone using at least one cutting parameter from a third cutting parameter set, which can be different from the first cutting parameter set or the second cutting parameter set. The third cutting parameter set can include a third cutting current and/or a third speed.
    Type: Grant
    Filed: May 15, 2009
    Date of Patent: September 24, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best, Peter V. Brahan, Gregory S. Wilson
  • Method and apparatus for improved cutting life of a plasma arc torch
    Patent number: 8525069
    Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a cavity in a front face at a first end of the electrode body, and an insert disposed in the cavity. The first end of the electrode body is formed of high purity copper containing at least 99.81% copper. The insert has a first end and a second end and is formed of a high emissivity material. A diameter of the first end of the insert is less than a diameter of a second end of the insert. An electrode is compressed to retain the insert using radial compression. The invention also includes a method for forming the electrode, and a method of operation of an electrode in a plasma torch.
    Type: Grant
    Filed: May 18, 2012
    Date of Patent: September 3, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Peter J. Twarog
  • Nozzle head with increased shoulder thickness
    Patent number: 8513565
    Abstract: A consumable for a plasma arc torch, such as a nozzle, having a body and a head defining a shoulder portion having a frusto-conical portion and a flared portion. The flared portion increases the cross-sectional thickness to provide a greater heat-conduction path for removal of heat generated by a plasma arc, thereby extending consumable life. The frusto-conical portion provides a sharper, pointier nozzle head to simultaneously increase the operator's visibility of the workpiece. Methods of making and using the consumables are also included.
    Type: Grant
    Filed: April 10, 2008
    Date of Patent: August 20, 2013
    Assignee: Hypertherm, Inc.
    Inventor: Zheng Duan
  • OPTIMIZATION AND CONTROL OF BEAM QUALITY FOR MATERIAL PROCESSING
    Publication number: 20130146569
    Abstract: Systems and methods are provided for adjusting a laser beam applied to a workpiece in a processing operation. A laser processing system receives the laser beam that is associated with a beam quality property. The laser processing system adjusts the laser beam to change the beam quality property based on a characteristic of the workpiece, a characteristic of the processing operation, or a combination thereof. The adjusted laser beam can also be delivered to the workpiece.
    Type: Application
    Filed: December 13, 2011
    Publication date: June 13, 2013
    Applicant: Hypertherm, Inc.
    Inventors: Kenneth J. Woods, Sanjay Garg, Tate S. Picard
  • Method and Apparatus for Cutting High Quality Internal Features and Contours
    Publication number: 20130119024
    Abstract: An automated method for cutting a plurality of hole features using a plasma arc torch system can be implemented on a computer numerical controller. The automated method can include the steps of: a) cutting a lead-in for a hole feature using a lead-in command speed based on a diameter of that hole feature and b) cutting a perimeter for the hole feature using a perimeter command speed greater than the corresponding lead-in command speed for the hole feature. The automated method can also include the step c) of repeating steps a) and b) for each additional hole feature having a same diameter or a different diameter.
    Type: Application
    Filed: December 18, 2012
    Publication date: May 16, 2013
    Applicant: Hypertherm, Inc.
    Inventor: Hypertherm, Inc.
  • Method and apparatus for cutting high quality internal features and contours
    Patent number: 8436270
    Abstract: An automated method for cutting a plurality of hole features using a plasma arc torch system can be implemented on a computer numerical controller. The automated method can include the steps of: a) cutting a lead-in for a hole feature using a lead-in command speed based on a diameter of that hole feature and b) cutting a perimeter for the hole feature using a perimeter command speed greater than the corresponding lead-in command speed for the hole feature. The automated method can also include the step c) of repeating steps a) and b) for each additional hole feature having a same diameter or a different diameter.
    Type: Grant
    Filed: September 30, 2011
    Date of Patent: May 7, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best, Peter V. Brahan, Gregory S. Wilson
  • HIGH POWER INDUCTOR AND IGNITION TRANSFORMER USING PLANAR MAGNETICS
    Publication number: 20130063234
    Abstract: Described are methods and systems for using a planar inductor that includes a magnetically conductive core, a first planar coil and a second planar coil. The first and second planar coils are attached to a first bridge, located about the core, and are composed of a conductive material. The first and second planar coils have at least one thermally conductive surface exposed to cooling fluid. The first planar coil, the first bridge and the second planar coil are formed from a first unitary section of conductive material. The second planar coil is positioned relative to the first planar coil in a spaced relationship, which is defined by a thickness of the first bridge. An upper surface of the first planar coil is oriented toward a lower surface of the second planar coil to define a first cooling channel between the first planar coil and the second planar coil.
    Type: Application
    Filed: July 6, 2012
    Publication date: March 14, 2013
    Applicant: HYPERTHERM, INC.
    Inventors: Girish R. Kamath, Norman LeBlanc, Wayne Chin, Paul Tillman
  • Plasma arc torch providing angular shield flow injection
    Patent number: 8395077
    Abstract: Plasma arc torches described herein include a torch tip with an improved nozzle that provides angular shield flow injection. In particular, the nozzle provides angular/conical impingement of a fluid (e.g., a shield gas) on an ionized plasma gas flowing through a plasma arc torch. Some of the torch tips described herein include a nozzle with a conical external shape combined with a shield with complementing internal geometry to form the angular fluid flow. As a result, a plasma arc torch including the improved nozzle have the benefits of a stabilized ionized plasma gas flow together with enhanced nozzle cooling and protection from reflecting slag during torch use.
    Type: Grant
    Filed: November 5, 2010
    Date of Patent: March 12, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Zheng Duan, Stephen M. Liebold, Aaron D. Brandt
  • Apparatus and method for a liquid cooled shield for improved piercing performance
    Patent number: 8389887
    Abstract: A shield for a plasma arc torch that pierces and cuts a metallic workpiece producing a splattering of molten metal directed at the torch, the shield protecting consumable components of the plasma arc torch from the splattering molten metal. The shield can include a body, a first surface of the body configured to be contact-cooled by a gas flow, a second surface of the body configured to be contact-cooled by a liquid flow, and a seal assembly configured to be secured to the body and disposed relative to the second surface configured to retain the liquid flow contact-cooling the second surface.
    Type: Grant
    Filed: September 29, 2008
    Date of Patent: March 5, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Stephen M. Liebold, Jon W. Lindsay, Brian J. Currier
  • Plasma insensitive height sensing
    Patent number: 8373425
    Abstract: A method for determining a distance between a first piece and a second piece includes measuring, at the first or second piece, an AC signal, and determining the distance based on the measured AC signal. A system for determining a distance between a first piece and a second piece includes a measuring device adapted to measure, at one or both of the first and second piece, an AC signal, and a signal processing device adapted to determine the distance based on the measured AC signal. The AC signal includes a DC offset.
    Type: Grant
    Filed: April 4, 2008
    Date of Patent: February 12, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Sanjay Garg, William J. Connally
  • Apparatus and Method for a Liquid Cooled Shield for Improved Piercing Performance
    Publication number: 20130026141
    Abstract: In some aspects, a retaining cap for a plasma arc torch can include a shell having an exterior surface that defines, at least in part, a first liquid coolant channel, a liner circumferentially disposed within the shell and having an interior surface that defines, at least in part, a second liquid coolant channel, and a gas flow channel defined at least in part by and located between the shell and the liner.
    Type: Application
    Filed: August 7, 2012
    Publication date: January 31, 2013
    Applicant: Hypertherm, Inc.
    Inventors: Stephen M. Liebold, Jon W. Lindsay, Brian J. Currier
  • High quality hole cutting using variable shield gas compositions
    Patent number: 8354610
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Grant
    Filed: September 29, 2011
    Date of Patent: January 15, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • High quality hole cutting using variable shield gas compositions
    Patent number: 8354609
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Grant
    Filed: December 22, 2008
    Date of Patent: January 15, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • Portable autonomous material processing system
    Patent number: 8350182
    Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.
    Type: Grant
    Filed: March 10, 2008
    Date of Patent: January 8, 2013
    Assignee: Hypertherm, Inc.
    Inventors: E. Michael Shipulski, Nicholas A. Sanders
  • Nozzle with exposed vent passage
    Patent number: 8338740
    Abstract: A nozzle for a plasma torch can include a body that has an inner surface, an outer surface, a proximal end, and an exit orifice at a distal end. The nozzle can also include a liner surrounded by the inner surface of the body. The liner can include a proximal end and an exit orifice at a distal end adjacent the exit orifice of the body. The nozzle can include at least one vent passage formed in the body. The vent passage can have an inlet formed in the inner surface of the body and an outlet formed in the outer surface of the body. The vent passage can be disposed between the proximal end of the body and the proximal end of the liner. The plasma arc torch can include a configuration that allows for increased electrode life and nozzle life for a vented high current plasma process.
    Type: Grant
    Filed: September 30, 2008
    Date of Patent: December 25, 2012
    Assignee: Hypertherm, Inc.
    Inventors: Stephen M. Liebold, Brian J. Currier
  • Method and apparatus for cutting high quality internal features and contours
    Patent number: 8338739
    Abstract: An automated method for cutting a plurality of hole features using a plasma arc torch system can be implemented on a computer numerical controller. The automated method can include the steps of: a) cutting a lead-in for a hole feature using a lead-in command speed based on a diameter of that hole feature and b) cutting a perimeter for the hole feature using a perimeter command speed greater than the corresponding lead-in command speed for the hole feature. The automated method can also include the step c) of repeating steps a) and b) for each additional hole feature having a same diameter or a different diameter.
    Type: Grant
    Filed: September 11, 2009
    Date of Patent: December 25, 2012
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best, Peter V. Brahan, Gregory S. Wilson
  • Plasma arc torch rotational assembly
    Patent number: 8304684
    Abstract: A plasma torch rotation assembly for relieving stress on a lead. The rotation assembly can include an outer housing, which can have a mounting surface adapted to be fixedly coupled to a torch mount. The rotation assembly can include an inner component disposed at least partially within the outer housing, and a bearing structure disposed between the outer housing and the inner component. The bearing structure can facilitate rotational movement of the outer housing relative to the inner component, about a longitudinal axis of the rotation assembly. The rotation assembly can include a torch adapter disposed near a first end of the inner component. The torch adapter can be adapted to mate with a plasma arc torch. The rotation assembly can include a receiving portion disposed at a second end of the inner component, the receiving portion adapted to receive at least a portion a lead.
    Type: Grant
    Filed: March 29, 2010
    Date of Patent: November 6, 2012
    Assignee: Hypertherm, Inc.
    Inventors: Brian J. Currier, Ross A. Smith, Jeremy Beliveau, Jon W. Lindsay