Search Patents
  • Plasma arc cutting system, including swirl rings, and other consumables, and related operational methods
    Patent number: 10638591
    Abstract: A plasma gas swirl ring for a liquid cooled plasma arc torch is provided. The swirl ring comprises a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface. The interior region of the body is configured to receive an electrode of the plasma arc torch. The swirl ring comprises a first opening disposed within a portion of the proximal end of the body, a second opening disposed about a central portion of the body, and a third opening comprising at least one swirling port disposed within a portion of the distal end of the body. The third opening is configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.
    Type: Grant
    Filed: April 11, 2017
    Date of Patent: April 28, 2020
    Assignee: Hypertherm, Inc.
    Inventor: John Peters
  • Integral spring consumables for plasma arc torch using blow forward contact starting system
    Patent number: 5897795
    Abstract: Disclosed is a novel method and structure for contact starting a plasma arc torch. A translatable, electrically conductive component such as a nozzle or swirl ring is biased into contact with an electrode by a compliant spring element. A pilot arc is formed by first passing current through the electrode/component interface. Thereafter, the component is translated under the influence of gas pressure in a plasma chamber formed between the electrode and component, compressing the compliant element and initiating the pilot arc. The spring element may be maintained integrally with the nozzle, swirl ring, or a retaining cap, facilitating removal and replacement of the spring element with consumable components of the torch. Exemplary spring elements include wave spring washers, finger spring washers, curved spring washers, helical compression springs, flat wire compression springs, and slotted conical discs.
    Type: Grant
    Filed: October 8, 1996
    Date of Patent: April 27, 1999
    Assignee: Hypertherm, Inc.
    Inventors: Zhipeng Lu, Richard W. Couch, Jr., Brian J. Currier
  • Apparatus and method for improved assembly concentricity in a plasma arc torch
    Patent number: 5841095
    Abstract: Disclosed is a method and structure for improving alignment of a plasma arc with an axial centerline of a plasma arc torch. At least one of an electrode and nozzle are mounted in respective bores of a cathode block and torch body using a radial spring element. By concentrically machining the bores along an axial centerline of the torch and centering the consumable components within the bores using the spring elements, an insert disposed in a tip of the electrode is axially aligned with an orifice formed in a tip of the nozzle. Asymmetric wear of the nozzle orifice due to a skewed arc path is markedly reduced or eliminated. The torch may be employed in computer controlled cutting and marking systems to produce components or workpieces with reduced dimensional and angular errors.
    Type: Grant
    Filed: October 28, 1996
    Date of Patent: November 24, 1998
    Assignee: Hypertherm, Inc.
    Inventors: Zhipeng Lu, Richard W. Couch, Jr., Jennifer L. Freeman
  • PLASMA ARC TORCH CUTTING COMPONENT WITH OPTIMIZED WATER COOLING
    Publication number: 20090026180
    Abstract: A nozzle, retaining cap, or shield for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle, retaining cap, or shield can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.
    Type: Application
    Filed: August 7, 2008
    Publication date: January 29, 2009
    Applicant: Hypertherm, Inc.
    Inventors: Yong Yang, David Jonathan Cook
  • Cartridge for a liquid-cooled plasma arc torch
    Patent number: 10561009
    Abstract: A liquid-cooled consumable cartridge for a plasma arc torch is provided. The cartridge includes (i) an electrode, (ii) a swirl ring with a first outer retaining feature and a second outer retaining feature on an exterior surface, where the electrode is secured to the swirl ring, and (iii) a nozzle with an inner retaining feature on an interior surface, where the inner retaining feature of the nozzle is mated with the first outer retaining feature of the swirl ring. The cartridge also includes a cartridge frame with an inner retaining feature on an interior surface and an outer retaining feature on an exterior surface. The inner retaining feature of the cartridge frame is mated with the second outer retaining feature of the swirl ring. The cartridge further includes a shield with an inner retaining feature on an interior surface mated with the outer retaining feature of the cartridge frame.
    Type: Grant
    Filed: August 4, 2016
    Date of Patent: February 11, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, E. Michael Shipulski
  • Circuitry and method for maintaining a plasma arc during operation of a plasma arc torch system
    Patent number: 5620617
    Abstract: An arc control circuit in a plasma arc torch, having an electrode and a nozzle, maintains a plasma arc during operation of the torch. The circuit includes a power supply electrically coupled to the electrode, nozzle and a workpiece. A logic device opens a power switch electrically coupling the nozzle to the power supply, disconnecting the nozzle from the supply, when a transferred arc is formed between the electrode and the workpiece. An amplifier is electrically connected to the power supply. The amplifier compares a sensed current to an operating current. The amplifier increases the output voltage of a power supply to maintain the operating current in coordination with an increasing distance between the workpiece and the torch. A comparator is electrically connected to a logic device and compares the output voltage of the power supply to a maximum voltage. When the output voltage of the power supply exceeds the maximum voltage, the comparator sets the logic device.
    Type: Grant
    Filed: October 30, 1995
    Date of Patent: April 15, 1997
    Assignee: Hypertherm, Inc.
    Inventors: Dennis M. Borowy, Jeffrey L. Peterson
  • Cooling plasma cutting system consumables and related systems and methods
    Patent number: 10827600
    Abstract: In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.
    Type: Grant
    Filed: April 13, 2018
    Date of Patent: November 3, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Sung Je Kim, Jesse A. Roberts, Shreyansh Patel
  • Plasma arc cutting system, consumables and operational methods
    Patent number: 10194517
    Abstract: The invention features methods and apparatuses for liquid cooling a plasma arc torch. An electrode is provided including a body having a longitudinal axis defining a first end, a second end, and a middle portion. The electrode includes a first sealing element disposed on an exterior of the body near the first end; a second sealing element disposed on the exterior of the body located in the middle portion, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.
    Type: Grant
    Filed: March 28, 2017
    Date of Patent: January 29, 2019
    Assignee: Hypertherm, Inc.
    Inventors: Madhura S. Mitra, Stephen M. Liebold, Harshawardhan Jogdand, Adam Chevalier, John Peters, Soumya Mitra
  • Gas mixtures for plasma arc torch cutting and marking systems
    Patent number: 5773788
    Abstract: A method of operating a plasma arc torch for marking a metallic workpiece spaced a stand-off distance from the torch utilizes a torch that includes a body, an electrode, and a nozzle mounted in the body so as to define a plasma chamber. The nozzle has a central passage and an exit orifice through which the transferred arc passes to the workpiece. The method also utilizes a plasma gas flow through the body to form a pilot arc in the plasma chamber and then to form a transferred arc between the electrode and the workpiece. The method includes forming the plasma gas flow with a selected mixture of hydrogen and an inert gas. The percentage of hydrogen in the selected mixture is between 0% and 35%. The percentage of inert gas in the selected mixture is between 100% and 65%. The inert gas may be argon.
    Type: Grant
    Filed: September 3, 1996
    Date of Patent: June 30, 1998
    Assignee: Hypertherm, Inc.
    Inventors: Zhipeng Lu, Elizabeth B. Hackett
  • Cooling plasma cutting system consumables and related systems and methods
    Patent number: 11622440
    Abstract: In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.
    Type: Grant
    Filed: July 12, 2019
    Date of Patent: April 4, 2023
    Assignee: Hypertherm, Inc.
    Inventors: Sung Je Kim, Jesse A. Roberts, Shreyansh Patel
  • Plasma Arch Torch Cutting Component With Optimized Water Cooling
    Publication number: 20080210669
    Abstract: A nozzle or retaining cap for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle or retaining cap can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.
    Type: Application
    Filed: February 8, 2008
    Publication date: September 4, 2008
    Applicant: Hypertherm, Inc.
    Inventors: Yong Yang, David Jonathan Cook, E. Michael Shipulski
  • Gas-Cooled Plasma Arc Cutting Torch
    Publication number: 20080217305
    Abstract: A method and apparatus for a gas-cooled plasma arc torch. Components of the torch can include an electrode, nozzle and a shield, each of which can be gas-cooled. The nozzle can be disposed relative to the electrode and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the nozzle to the cooling gas flow channel during operation of the torch. The shield can be disposed relative to the nozzle and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the shield to the cooling gas flow channel during operation of the torch.
    Type: Application
    Filed: February 15, 2008
    Publication date: September 11, 2008
    Applicant: Hypertherm, Inc.
    Inventor: Nicholas A. Sanders
  • Cooling plasma cutting system consumables and related systems and methods
    Patent number: 9967964
    Abstract: In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.
    Type: Grant
    Filed: May 29, 2015
    Date of Patent: May 8, 2018
    Assignee: Hypertherm, Inc.
    Inventors: Sung Je Kim, Jesse A. Roberts, Shreyansh Patel
  • Gas-cooled plasma arc cutting torch
    Patent number: 8089025
    Abstract: A method and apparatus for a gas-cooled plasma arc torch. Components of the torch can include an electrode, nozzle and a shield, each of which can be gas-cooled. The nozzle can be disposed relative to the electrode and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the nozzle to the cooling gas flow channel during operation of the torch. The shield can be disposed relative to the nozzle and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the shield to the cooling gas flow channel during operation of the torch.
    Type: Grant
    Filed: February 15, 2008
    Date of Patent: January 3, 2012
    Assignee: Hypertherm, Inc.
    Inventor: Nicholas A. Sanders
  • Plasma arc torch cutting component with optimized water cooling
    Patent number: 8829385
    Abstract: A nozzle, retaining cap, or shield for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle, retaining cap, or shield can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.
    Type: Grant
    Filed: August 7, 2008
    Date of Patent: September 9, 2014
    Assignee: Hypertherm, Inc.
    Inventors: Yong Yang, David Jonathan Cook
  • Plasma arc cutting torch ignition circuit and method providing a forced arc transfer function
    Patent number: 5548097
    Abstract: Circuitry and methods for reducing nozzle wear during starting of a plasma arc torch, even with a large standoff distance from a workpiece is described. The invention features a method of starting a plasma arc torch for cutting a workpiece using a pilot voltage to ionize a plasma gas and generate a pilot arc between an electrode and a nozzle. The method expedites the transfer of the arc from the nozzle to the workpiece by passing a generally smooth signal through the electrode before, during and after the arc transfers to the workpiece. A high frequency high voltage starting circuit is constructed with a pilot arc circuit isolated from a transfer arc circuit. A signal is generated which has a magnitude sufficient to ionizes a plasma gas to generate a pilot arc between the electrode and the nozzle and has a magnitude which generally increases after the pilot arc has been generated in order to expedite the transfer of the arc.
    Type: Grant
    Filed: December 22, 1994
    Date of Patent: August 20, 1996
    Assignee: Hypertherm, Inc.
    Inventors: Richard W. Couch, Jr, Lifeng Luo, Jeffrey L. Peterson
  • Automatic gas control for a plasma arc torch
    Publication number: 20060163216
    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: Application
    Filed: January 27, 2006
    Publication date: July 27, 2006
    Applicant: Hypertherm, Inc.
    Inventors: Aaron Brandt, Christopher Passage, Shane Selmer, Girish Kamath, Guy Best, Stephen Liebold, Jon Lindsay, Zheng Duan
  • Forward Flow, High Access Consumables for a Plasma Arc Cutting Torch
    Publication number: 20120055906
    Abstract: A nozzle for a plasma arc cutting torch includes a substantially hollow, elongated body capable of receiving an electrode. The nozzle body defines a longitudinal axis and has a length along the axis from a first end of the nozzle body to a second end of the nozzle body. The nozzle also includes a plasma exit orifice disposed at the first end of the body. The first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3.
    Type: Application
    Filed: September 9, 2011
    Publication date: March 8, 2012
    Applicant: Hypertherm, Inc.
    Inventors: E. Michael Shipulski, Nicholas A. Sanders, Jay L. Jason, Jonathan Mather, Peter J. Twarog
  • Swirl ring and contact element for a plasma arc torch cartridge
    Patent number: 10335888
    Abstract: A swirl ring for a plasma arc torch includes a body configured to at least partially surround and slidingly engage an electrode of the plasma arc torch. The body includes a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, and at least one protuberance extending from the second end in a direction of the longitudinal axis. The at least one protuberance is configured to engage a switch of the plasma arc torch for sensing a presence of a swirl ring in the plasma arc torch.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: July 2, 2019
    Assignee: Hypertherm, Inc.
    Inventors: Yu Zhang, Jesse A. Roberts, Zheng Duan, Michael Scheller, David Agan, Steven Moody, Stephen T. Eickhoff, Garrett K. Quillia
  • Method and apparatus for automatic gas control for a plasma arc torch
    Publication number: 20080006614
    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: Application
    Filed: September 7, 2007
    Publication date: January 10, 2008
    Applicant: Hypertherm, Inc.
    Inventors: Aaron Brandt, Christopher Passage, Shane Selmer, Girish Kamath, Guy Best, Stephen Liebold, Jon Lindsay, Zheng Duan
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