Search Patents
  • Swirl control through electrode geometry
    Patent number: 12245354
    Abstract: A translatable electrode for use in a cartridge assembly for a contact start plasma arc torch including an electrode body having a longitudinal axis and including a proximal end and a distal end. The proximal end including a spiral groove and a contact surface at a proximal end face shaped to electrically communicate with a cathodic element. The translatable electrode also including at least one emissive insert disposed within the distal end of the electrode body and proximate a distal end face. The translatable electrode including at least one baffle disposed between the proximal and distal end of the electrode body. The translatable electrode also including a gas flow dampening region disposed circumferentially about the distal end and adjacent the distal end face and positioned between the at least one baffle and the distal end face.
    Type: Grant
    Filed: December 23, 2021
    Date of Patent: March 4, 2025
    Assignee: Hypertherm, Inc.
    Inventors: Faraz Mehdi, Yu Zhang, Steven Moody, Brenda Melius, Jesse Roberts, David J. Cook
  • Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes
    Patent number: 8035055
    Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material that defines a longitudinal axis and a distal end for housing an emissive element. The electrode includes a second end positioned adjacent the electrode body. The second end defines an extensive portion having a first length along a first direction and a second length along a second direction. The second length is greater than the first length. A component for use with the electrode includes a hollow body element having an interior surface with one or more of a contour, step, or flange that defines a shaped opening capable of slideably receiving a complementary-shaped portion of an electrode body.
    Type: Grant
    Filed: February 20, 2007
    Date of Patent: October 11, 2011
    Assignee: Hypertherm, Inc.
    Inventors: Peter John Twarog, Jonathan P. Mather, Stephen T. Eickhoff, Jesse Roberts
  • Composite electrode for a plasma arc torch
    Patent number: 7659488
    Abstract: A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.
    Type: Grant
    Filed: July 28, 2006
    Date of Patent: February 9, 2010
    Assignee: Hypertherm, Inc.
    Inventors: David J. Cook, Kirk H. Ferland, Charles M. Hackett, Yong Yang, Richard W. Couch, Jr., Zhipeng Lu
  • Plasma arc torch having an electrode with internal passages
    Patent number: 7375302
    Abstract: An electrode for a plasma arc cutting torch which minimizes the deposition of high emissivity material on the nozzle, reduces electrode wear, and improves cut quality. The electrode has a body having a first end, a second end in a spaced relationship relative to the first end, and an outer surface extending from the first end to the second end. The body has an end face disposed at the second end. The electrode also includes at least one passage extending from a first opening in the body to a second opening in the end face.
    Type: Grant
    Filed: November 16, 2004
    Date of Patent: May 20, 2008
    Assignee: Hypertherm, Inc.
    Inventors: Peter J. Twarog, Charles M. Hackett, David J. Cook, Bruce P. Altobelli, David L. Bouthillier
  • Plasma ARC Torch Electrode with Symmetrical Plasma Gas Flow
    Publication number: 20150021302
    Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.
    Type: Application
    Filed: September 27, 2013
    Publication date: January 22, 2015
    Applicant: Hypertherm, Inc.
    Inventors: Yu Zhang, Zheng Duan
  • Plasma ARC torch electrode with symmetrical plasma gas flow
    Patent number: 9480139
    Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.
    Type: Grant
    Filed: September 27, 2013
    Date of Patent: October 25, 2016
    Assignee: Hypertherm, Inc.
    Inventors: Yu Zhang, Zheng Duan
  • Apparatus and process for cooling a plasma arc electrode
    Patent number: 4902871
    Abstract: In a plasma arc torch, an electrode is movable axially into and out of electrical connection with an anode, typically a nozzle secured to one end of a torch body. A flow of pressurized plasma gas is directed to a plasma chamber between the electrode and the nozzle, preferably through a replaceable swirl ring that closely surrounds and guides the electrode at a larger diameter shoulder portion of the electrode. A gas flow passage, preferably a spiral passage machined on the outer side surface of the shoulder portion, diverts a portion of the gas flow from the plasma chamber to a region above the electrode where it is vented to atmosphere. The passage is sufficiently constricted that a substantial pressure drop appears along the path, while at the same time allowing a sufficient flow to produce the desired cooling. The revolutions of the spiral are preferably closely spaced to enhance the surface area of the electrode in a heat transfer relationship with the cooling gas flow.
    Type: Grant
    Filed: September 26, 1988
    Date of Patent: February 20, 1990
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, Richard W. Couch, Jr.
  • Electrode for high current density plasma arc torch
    Patent number: 5310988
    Abstract: The diameter of a hafnium insert press fit into the bottom end of a copper electrode varies as a function of the level of current carried by the electrode. The diameter is the minimum necessary to support emission at that current level while also protecting the copper body against attack by the arc. The insert is generally circular and preferably extends completely through the bottom wall to a circulating flow of cooling water at a hollow interior of the electrode. The bottom wall includes an annular recess in a portion of the copper wall surrounding the insert. A coolant inlet tube extends into the recess in a spaced relationship to provide a high flow velocity of the coolant over the interior rear surface of the electrode.
    Type: Grant
    Filed: May 20, 1992
    Date of Patent: May 10, 1994
    Assignee: Hypertherm, Inc.
    Inventors: Richard W. Couch, Jr., Nichols A. Sanders, Lifeng Luo, Zhipeng Lu, Patrik Backander, John Sobr
  • Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes
    Patent number: 9492883
    Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.
    Type: Grant
    Filed: January 6, 2012
    Date of Patent: November 15, 2016
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Nicholas A. Sanders, Jon W. Lindsay, Peter Twarog, E. Michael Shipulski, Zheng Duan, David Jonathan Cook
  • Electrode for a Contact Start Plasma Arc Torch and Contact Start Plasma Arc Torch Employing Such Electrodes
    Publication number: 20120181257
    Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.
    Type: Application
    Filed: January 6, 2012
    Publication date: July 19, 2012
    Applicant: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Nicholas A. Sanders, Jon W. Lindsay, Peter Twarog, E. Michael Shipulski, Zheng Duan, David Jonathan Cook
  • APPARATUS AND METHOD FOR SECURING A PLASMA TORCH ELECTRODE
    Publication number: 20150021300
    Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.
    Type: Application
    Filed: September 27, 2013
    Publication date: January 22, 2015
    Applicant: Hypertherm, Inc.
    Inventors: Zheng Duan, Yu Zhang, Peter Twarog, Sung Je Kim, Michael F. Kornprobst, Josh Murray, Jeffery Cornish
  • Apparatus and method for securing a plasma torch electrode
    Patent number: 10542614
    Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.
    Type: Grant
    Filed: September 27, 2013
    Date of Patent: January 21, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Zheng Duan, Yu Zhang, Peter Twarog, Sung Je Kim, Michael F. Kornprobst, Josh Murray, Jeffrey Cornish
  • Internally energized electrode of a plasma arc torch
    Patent number: 10561010
    Abstract: A coolant tube for a plasma arc torch is provided. The coolant tube includes an elongated coolant tube body including a distal portion configured to engage an electrode and a proximal portion configured to engage a body of the plasma arc torch. The coolant tube also includes a first electrically conductive element coupled to the distal portion of the elongated coolant tube body. The first electrically conductive element is configured to physically contact an electrode. The coolant tube further includes a second electrically conductive element coupled to the proximal portion of the elongated coolant tube body. The second electrically conductive element is configured to physically contact the body of the plasma arc torch. The elongated coolant tube body defines a current path and a fluid path between the body of the plasma arc torch and the electrode.
    Type: Grant
    Filed: December 21, 2016
    Date of Patent: February 11, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Micah Roberts, Christopher Pillsbury, Steve Dunbar
  • Plasma Torch Electrode with Improved Cooling Capability
    Publication number: 20110259855
    Abstract: An electrode for a plasma arc torch includes a hollow elongated body having an open end and a closed end and an end face located at the closed end inside of the hollow elongated body. The end face has a center portion. A plurality of heat exchanging elements are in thermal communication with the end face. The heat exchanging elements have side walls defining an elongated channel between adjacent heat exchanging elements. The elongated channel extends radially from the center portion to an inner surface of the elongated body. The elongated channel provides a thermally conductive path that transfers sufficient heat from the elongated body to a cooling fluid during an operation of the plasma arc torch to prevent premature failure of the electrode.
    Type: Application
    Filed: April 19, 2011
    Publication date: October 27, 2011
    Applicant: HYPERTHERM, INC.
    Inventor: Yong Yang
  • Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes
    Patent number: 9736918
    Abstract: A swirl ring component of a contact start plasma arc torch is provided. The swirl ring component includes a hollow body formed of a front portion and a rear portion along a longitudinal axis and defining an exterior surface and an interior surface. The swirl ring component also includes one or more gas passageways extending from the exterior surface to the interior surface in the front portion of the hollow body and a resilient element disposed relative to the interior surface in the rear portion of the hollow body and configured to pass at least a pilot arc current to an electrode body. The swirl ring component further includes a shoulder portion configured to retain the resilient element in the hollow body.
    Type: Grant
    Filed: October 18, 2016
    Date of Patent: August 15, 2017
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan P. Mather, Stephen T. Eickhoff, Jesse A. Roberts
  • Electrode for a plasma arc torch
    Patent number: 5464962
    Abstract: An insert securely disposed in a bottom end of an electrode has an exposed emission surface shaped to define a recess in the insert, wherein the recess is initially dimensioned as a function of the operating current level of the torch, the diameter of the insert, and the plasma gas flow pattern in the torch. The electrode has an elongated body formed of a high thermal conductivity material such as copper, and a bore disposed in the bottom end of the body along a central axis. The insert is formed of a high thermionic emissivity material, such as hafnium, and securely disposed in the bore with the emission surface exposed. The emission surface may be initially shaped by removing a predetermined amount of the high thermionic emissivity material from the insert to define a generally concave recess, a generally cylindrical recess or other shapes. When used in a torch, the electrode provides for reduced deposition of the high thermionic emissivity material on the nozzle, thereby reducing nozzle wear in the torch.
    Type: Grant
    Filed: July 29, 1994
    Date of Patent: November 7, 1995
    Assignee: Hypertherm, Inc.
    Inventors: Lifeng Luo, Richard W. Couch, Jr.
  • Coolant tube for use in a liquid-cooled electrode disposed in a plasma arc torch
    Patent number: 5756959
    Abstract: A coolant tube for a liquid-cooled electrode disposed a plasma arc torch does not become damaged during an electrode blow-out condition. The coolant tube includes a hollow member and a substantially solid member. The hollow member has a first end, a second end and a coolant passage extending between the first and second ends. The first end can be secured within the torch such that the coolant tube is disposed adjacent the interior surface of the electrode and such that the coolant passage is in fluid communication with a coolant supply. The substantially solid member extends from the second end of the hollow member and has at least one flow restriction orifice extending therethrough. Each flow restriction orifice is fluid communication with the coolant passage for providing at least one high velocity jet of coolant to the interior surface of the electrode.
    Type: Grant
    Filed: October 28, 1996
    Date of Patent: May 26, 1998
    Assignee: Hypertherm, Inc.
    Inventors: Jennifer L. Freeman, Zhipeng Lu, Richard W. Couch, Jr., Roger L. Kenyon
  • Electrode for a plasma arc torch
    Patent number: 5601734
    Abstract: An insert securely disposed in a bottom end of an electrode has an exposed emission surface shaped to define a recess in the insert, wherein the recess is initially dimensioned as a function of the operating current level of the torch, the diameter of the insert, and the plasma gas flow pattern in the torch. The electrode has an elongated body formed of a high thermal conductivity material such as copper, and a bore disposed in the bottom end of the body along a central axis. The insert is formed of a high thermionic emissivity material, such as hafnium, and securely disposed in the bore with the emission surface exposed. The emission surface may be initially shaped by removing a predetermined amount of the high thermionic emissivity material from the insert to define a generally concave recess, a generally cylindrical recess or other shapes. When used in a torch, the electrode provides for reduced deposition of the high thermionic emissivity material on the nozzle, thereby reducing nozzle wear in the torch.
    Type: Grant
    Filed: November 6, 1995
    Date of Patent: February 11, 1997
    Assignee: Hypertherm, Inc.
    Inventors: Lifeng Luo, Richard W. Couch, Jr.
  • Proceses and apparatus for reducing electrode wear in a plasma arc torch
    Patent number: 5070227
    Abstract: A process and apparatus for reducing wear of an electrode in a plasma arc torch involves altering the gas flow in a plasma chamber surrounding the electrode immediately before and continuing after cutting of the current that sustains the arc. The altering includes closing off the gas flow upstream of the chamber, switching from a swirling flow to a radial/axial flow through the plasma chamber, reducing the arc current level in conjunction with either of the above, and venting the plasma chamber to rapidly change the gas flow and pressure in the chamber. The interval is sufficient to reduce electrode wear, but short enough that the arc remains stabilized until cut-off. In the flow stop mode, a solenoid valve is placed on an inlet tube for the plasma gas. For venting, a vent tube and another solenoid valve are added to the torch.
    Type: Grant
    Filed: April 24, 1990
    Date of Patent: December 3, 1991
    Assignee: Hypertherm, Inc.
    Inventors: Lifeng Luo, Nicholas A. Sanders, Richard W. Couch, Jr.
  • Process and apparatus for reducing electrode wear in a plasma arc torch
    Patent number: 5166494
    Abstract: A process and apparatus for reducing wear of an electrode in a plasma arc torch involves altering the gas flow in a plasma chamber surrounding the electrode immediately before and continuing after cutting of the current that sustains the arc. The altering includes closing off the gas flow upstream of the chamber, switching from a swirling flow to a radial/axial flow through the plasma chamber, reducing the arc current level in conjunction with either of the above, the venting the plasma chamber to rapidly change the gas flow and pressure in the chamber. The interval is sufficient to reduce electrode wear, but short enough that the arc remains stabilized until cut-off. In the flow stop mode, a solenoid valve is placed on an inlet tube for the plasma gas. Flow altering also occurs on start up. A gas preflow is established prior to pilot arc ignition. On transfer, the flow increases to its full operating value in conjunction with an increase in the arc current. The preflow can be axial, or partially axial.
    Type: Grant
    Filed: April 12, 1991
    Date of Patent: November 24, 1992
    Assignee: Hypertherm, Inc.
    Inventors: Lifeng Luo, Nicholas A. Sanders, Richard W. Couch, Jr.
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