Search Patents
  • Forward flow, high access consumables for a plasma arc cutting torch
    Patent number: 8981253
    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: Grant
    Filed: September 9, 2011
    Date of Patent: March 17, 2015
    Assignee: Hypertherm, Inc.
    Inventors: E. Michael Shipulski, Nicholas A. Sanders, Jay L. Jason, Jonathan Mather, Peter J. Twarog
  • Interchangeable power contact for a plasma arc cutting system
    Patent number: 9781816
    Abstract: A power contact for a liquid-cooled plasma arc cutting system is provided. The cutting system includes a torch body and a lower torch assembly. The power contact comprises a substantially hollow body including an upper portion and a lower portion, and an external surface of the upper portion of the hollow body configured to matingly engage the torch body. The power contact further includes a thread region disposed on an internal surface of the hollow body. The thread region is configured to retain an electrode holder of the lower torch assembly of the plasma arc cutting system to matingly engage the lower torch assembly and secure the lower torch assembly to the torch body.
    Type: Grant
    Filed: October 20, 2015
    Date of Patent: October 3, 2017
    Assignee: Hypertherm, Inc.
    Inventors: David J. Cook, David L. Bouthillier
  • Plasma arch torch cutting component with optimized water cooling
    Patent number: 8772667
    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: Grant
    Filed: February 8, 2008
    Date of Patent: July 8, 2014
    Assignee: Hypertherm, Inc.
    Inventors: Yong Yang, David Jonathan Cook, E. Michael Shipulski
  • Consumable cartridge for a plasma arc cutting system
    Patent number: 11278983
    Abstract: A frame for a replaceable, unitary consumables cartridge configured for installation into a plasma arc torch. The frame includes a hollow body adapted to receive a translatable contact start electrode. The body has an internal surface and an external surface and includes: a substantially cylindrical metallic core; an electrically insulative overmolded plastic casing at least substantially surrounding a circumference of a distal end of the substantially cylindrical metallic core; and a set of flow passages fluidly connecting the external surface of the hollow body and the internal surface of the hollow body, the flow passages offset to impart a swirling fluid flow pattern to a plasma gases passing therethrough.
    Type: Grant
    Filed: November 7, 2019
    Date of Patent: March 22, 2022
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, Peter J. Twarog, E. Michael Shipulski, Yu Zhang
  • Controlling plasma arc torches and related systems and methods
    Patent number: 10722971
    Abstract: In some aspects, methods of initiating a plasma arc of a plasma arc torch to pierce a workpiece and detecting plasma piercing through the workpiece to begin a cutting sequence can include calculating a pulse width modulation characteristic of an electrical signal associated with a plasma arc between an electrode of a plasma arc torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period of a workpiece piercing sequence; comparing the characteristic to a threshold value; and responsive to determining that a calculated characteristic meets and/or exceeds the threshold value, ending the workpiece piercing sequence and beginning the cutting sequence and causing the plasma arc torch to move relative to the workpiece to form a cut.
    Type: Grant
    Filed: October 6, 2016
    Date of Patent: July 28, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Soumya Mitra, John Peters
  • Swirl ring for a plasma arc torch
    Patent number: 10645791
    Abstract: A swirl ring for a plasma arc torch is provided. The swirl ring comprises a hollow body having a distal end and a proximal end and configured to receive at least a portion of an electrode within the hollow body. The swirl ring also comprises a first set of flange segments circumferentially disposed on an interior surface of the hollow body. The first set of flange segments extend radially inward from the interior surface and shaped to retain a first surface of a sealing member. The swirl ring further comprises a second set of flange segments circumferentially disposed on the interior surface of the hollow body. The second set of flange segments extend radially inward from the interior surface and shaped to retain a second surface of the sealing member.
    Type: Grant
    Filed: December 22, 2017
    Date of Patent: May 5, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Dennis Kulakowski, Christopher Pillsbury, David W. Lewis
  • METHOD AND APPARATUS FOR AUTOMATIC GAS CONTROL FOR A PLASMA ARCH TORCH
    Publication number: 20080210670
    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: April 25, 2008
    Publication date: September 4, 2008
    Applicant: 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
  • Method and apparatus for automatic gas control for a plasma arc torch
    Patent number: 8809728
    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: September 7, 2007
    Date of Patent: August 19, 2014
    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
  • Cost effective cartridge for a plasma arc torch
    Patent number: 10582605
    Abstract: A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.
    Type: Grant
    Filed: August 12, 2015
    Date of Patent: March 3, 2020
    Assignee: Hypertherm, Inc.
    Inventors: Yu Zhang, Zheng Duan, Mahyar Esmaili, Mike Kornprobst, Brett Hansen, Garrett Quillia
  • NOZZLE WITH EXPOSED VENT PASSAGE
    Publication number: 20100078408
    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: Application
    Filed: September 30, 2008
    Publication date: April 1, 2010
    Applicant: HYPERTHERM, INC.
    Inventors: Stephen M. Liebold, Brian J. Currier
  • Nozzle for a plasma arc torch with an exit orifice having an inlet radius and an extended length to diameter ratio
    Patent number: 5977510
    Abstract: A plasma arc torch includes a torch body and a nozzle mounted relative to an electrode at a first end of the torch body to define a plasma chamber. The torch body includes a plasma gas flow path for directing a plasma gas from a plasma gas inlet to a plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion defining a cavity and a substantially solid, head portion formed integrally with the body portion defining an exit orifice extending from the chamber. The exit orifice has a converging inlet and an outlet, where the inlet has a radius of curvature, and the exit orifice has a length to diameter ratio of greater than 2.5.
    Type: Grant
    Filed: April 27, 1998
    Date of Patent: November 2, 1999
    Assignee: Hypertherm, Inc.
    Inventor: Jon W. Lindsay
  • Cost effective cartridge for a plasma arc torch
    Patent number: 11770891
    Abstract: A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.
    Type: Grant
    Filed: May 6, 2019
    Date of Patent: September 26, 2023
    Assignee: Hypertherm, Inc.
    Inventors: Yu Zhang, Zheng Duan, Mahyar Esmaili, Mike Kornprobst, Brett Hansen, Garrett Quillia
  • Method and Apparatus for Automatic Gas Control for a Plasma Arc Torch
    Publication number: 20080169272
    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: February 29, 2008
    Publication date: July 17, 2008
    Applicant: 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
  • High access consumables for a plasma arc cutting system
    Patent number: 9560732
    Abstract: A nozzle for a plasma arc torch is provided. The nozzle includes a substantially hollow, elongated nozzle body capable of receiving an electrode, the body defining a longitudinal axis, a distal end, and a proximal end. The nozzle also includes a swirl sleeve attachable to an interior surface of the nozzle body, the swirl sleeve configured to impart a swirling motion to a gas introduced to the nozzle. The nozzle additionally includes a nozzle tip connected to the proximal end of the nozzle body, a nozzle shield, and an insulator configured to connect the nozzle tip and the nozzle shield to electrically insulate the nozzle shield and the nozzle tip from one another while transferring thermal energy therebetween.
    Type: Grant
    Filed: January 30, 2015
    Date of Patent: January 31, 2017
    Assignee: Hypertherm, Inc.
    Inventors: E. Michael Shipulski, Nicholas A. Sanders, Jay Jason, Jonathan P. Mather, Peter J. Twarog, Clifford Glenn Darrow
  • Systems and methods for stabilizing plasma gas flow in a plasma arc torch
    Patent number: 9820371
    Abstract: A nozzle of a plasma arc torch is provided. The nozzle is configured to reduce fluid pressure surging in a nozzle plenum. The nozzle comprises a nozzle body having a proximal end and a distal end. The nozzle plenum is defined between the nozzle body and an electrode of the plasma arc torch. The nozzle includes a nozzle plenum gas inlet located at the proximal end of the nozzle body, a plasma gas exit orifice located at the distal end of the nozzle body, a plasma gas passageway fluidly connecting the nozzle plenum gas inlet to the plasma gas exit orifice, and an isolation chamber fluidly connected to the plasma gas passageway and the nozzle plenum. The isolation chamber is sized to receive a volume of substantially stagnant gas to reduce the fluid pressure surging in the nozzle plenum.
    Type: Grant
    Filed: May 12, 2016
    Date of Patent: November 14, 2017
    Assignee: Hypertherm, Inc.
    Inventor: Adam Chevalier
  • Swirl ring and flow control process for a plasma arc torch
    Patent number: 5170033
    Abstract: A process and apparatus for reducing wear of an electrode in a plasma arc torch involves providing a substantial pressure drop in a flow of plasma gas from the torch to a plasma arc chamber defined by the electrode and a nozzle. The pressure drop is immediately before the plasma arc chamber. There is also a small, localized supply of the plasma gas located between the pressure drop and the plasma chamber. The supply is sufficient to stabilize the arc when the gas flow is cut off upstream of the pressure drop and the arc current is cut off very shortly thereafter. The pressure drop is small enough to permit an adequate flow of plasma gas to the plasma arc chamber during normal operations, but large enough to isolate residual gas in the torch from the plasma arc chamber when the arc current is cut off. The apparatus is preferably a swirl ring with an annular pre-chamber fed by a set of choke holes to feed gas to the chamber and create the pressure drop.
    Type: Grant
    Filed: April 12, 1991
    Date of Patent: December 8, 1992
    Assignee: Hypertherm, Inc.
    Inventors: Richard W. Couch, Jr., Lifeng Luo, Nicholas A. Sanders
  • 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
  • Nozzle for plasma arc torch
    Publication number: 20020135283
    Abstract: An output structure for material processing apparatus facilitates field replacement of consumable components, while maintaining important alignments. Contoured surfaces within the output structure mate with corresponding contoured surfaces on the consumable components, thereby facilitating alignment of the consumable components with an axis of the output structure. Material processing apparatus employing such surfaces include lasers and plasma arc torches and, with proper alignment, apparatus performance is improved. Typical consumable components include electrodes, swirl rings, nozzles, and shields. The consumable components can be axially translatable with respect to each other, thereby promoting contact starting of a plasma arc torch. An installation tool for consumable components also serves to align the components with an axis of the output structure.
    Type: Application
    Filed: May 21, 2002
    Publication date: September 26, 2002
    Applicant: HYPERTHERM, INC.
    Inventors: Charles M. Hackett, Yutaka Nakano, Zhipeng Lu, Aaron D. Brandt, Brian J. Currier, Kenneth J. Woods
  • 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 of improving electrode life by simultaneously controlling plasma gas composition and gas flow
    Patent number: 9642237
    Abstract: A method of operating a plasma arc torch system is provided. A first plasma gas supply source, a second plasma gas supply source, and a control unit are provided. A first plasma gas composition is flowed through a first plasma gas flow path, and a plasma arc is generated using the first plasma gas composition. After arc generation, the plasma gas composition is changed to a second plasma gas composition, and the plasma gas flow path is changed to a second plasma gas flow path, wherein the second plasma gas flow path is different from the first plasma gas flow path. The plasma arc is sustained using the second plasma gas composition. The first and second plasma gas flow paths are both at least partially disposed within the plasma arc torch.
    Type: Grant
    Filed: May 20, 2014
    Date of Patent: May 2, 2017
    Assignee: Hypertherm, Inc.
    Inventors: John Peters, Jon W. Lindsay
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