# US 10,321,551 B2 · Cost effective cartridge for a plasma arc torch

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- Number: US 10,321,551 B2
- Document ID: US10321551B2
- Status: Granted
- Kind: B2
- Application number: 15/043,028
- Filed: 2016-02-12
- Published: 2016-06-09
- Granted: 2019-06-11
- Earliest claimed: 2014-08-12
- Assignees: Hypertherm, Inc.
- Applicants: Hypertherm, Inc.
- Inventors: Yu Zhang; Zheng Duan; Mahyar Esmaili; Mike Kornprobst; Brett Hansen; Garrett Quillia
- Web page: https://patentgrep.com/patent/US10321551B2

## CPC

- H05H 1/34: Details, e.g. electrodes, nozzles
- B23K 10/02: Plasma welding
- H05H 1/3457: {Nozzle protection devices}
- H05H 1/3468: {Vortex generators}
- H05H 1/3489: {Means for contact starting}
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM

## Abstract

A consumable cartridge for a plasma arc torch is provided. The consumable cartridge includes an outer component defining a substantially hollow body, an inner component disposed substantially within the hollow body of the outer component, and a hollow region between the rear portion of the inner component and the outer component. The inner component includes a forward portion configured to axially secure and rotatatably engage the outer component to the inner component and a rear portion substantially suspended within the hollow body of the outer component. The rear portion is axially secured and rotatably engaged with the outer component via the forward portion. The hollow region is configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

## Claims

### Claim 1

A consumable cartridge for a plasma arc torch, the consumable cartridge comprising:
an outer component defining a substantially hollow body;
an inner component disposed substantially within the hollow body of the outer component, the inner component comprising:
a forward portion configured to axially secure and rotatatably engage the outer component with respect to the forward portion of the inner component; and
a rear portion substantially suspended within and without being in direct physical contact with the hollow body of the outer component, the rear portion axially secured and rotatably engaged with respect to the outer component via the forward portion; and
a hollow region between the rear portion of the inner component and the outer component, the hollow region configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

### Claim 2 (depends on 1)

The consumable cartridge of claim 1, wherein the forward portion of the inner component includes a means for enabling axial securement and rotatable engagement of the outer component thereto, the means for enabling being dimensioned to permit independent rotation of the inner and outer components relative to each other.

### Claim 3 (depends on 1)

The consumable cartridge of claim 1, wherein the outer component comprises at least one of a shield, an insulating component, a retaining cap or a cap sleeve.

### Claim 4 (depends on 1)

The consumable cartridge of claim 1, wherein the inner component comprises at least one of a crown, a swirl ring, an electrode or a nozzle.

### Claim 5 (depends on 1)

The consumable cartridge of claim 1, wherein the rear portion of the inner component is configured to substantially surround and physically contact at least a portion of the cathode.

### Claim 6 (depends on 5)

The consumable cartridge of claim 5, wherein the rear portion of the inner component comprises a cavity configured to receive the at least a portion of the cathode extending into the cartridge.

### Claim 7 (depends on 1)

The consumable cartridge of claim 1, wherein the axial securing and rotatable engaging of the outer component to the inner component is by one of crimping, snap fitting, frictional fitting or threading.

### Claim 8 (depends on 1)

The consumable cartridge of claim 1, wherein the inner component further comprises one or more fins disposed on an external surface of the inner component.

### Claim 9 (depends on 1)

The consumable cartridge of claim 1, wherein at least one of the rear portion of the inner component or the outer component comprises at least one thread for engaging the torch head.

### Claim 10 (depends on 1)

The consumable cartridge of claim 1, wherein the rear portion of the inner component has no means for enabling axial securement and rotatable engagement with the outer component.

### Claim 11 (depends on 1)

The consumable cartridge of claim 1, wherein the outer component provides an electrical path for a pilot arc current of the plasma arc torch.

### Claim 12 (depends on 1)

The consumable cartridge of claim 1, wherein the outer component comprises one or more fins disposed on an internal surface of the outer component.

### Claim 13

A cartridge consumable for a plasma arc torch, the cartridge consumable comprising:
an outer component defining a substantially hollow body;
an inner component, comprising at least an electrode, disposed within the hollow body of the outer component, the inner component comprising:
a forward portion;
an engagement feature disposed on the forward portion of the inner component, the engagement feature adapted to engage the forward portion of the inner component with the outer component by axially constraining the outer component relative to the forward portion of the inner component while permitting independent rotation of the inner and outer components relative to each other; and
a rear portion substantially suspended within and without being in direct physical contact with the hollow body of the outer component upon the engagement of the forward portion of the inner component with the outer component via the engagement feature.

### Claim 14 (depends on 13)

The cartridge of claim 13, wherein the inner component further comprises a crown that is substantially locked into position upon assembly into the plasma arc torch.

### Claim 15 (depends on 13)

The cartridge consumable of claim 13, wherein the outer component comprises a metallic retaining cap and an electrically insulative cap sleeve overmolded onto the retaining cap.

### Claim 16 (depends on 13)

The cartridge consumable of claim 13, further comprising a shield connected to the inner component via the outer component.

### Claim 17 (depends on 16)

The cartridge consumable of claim 16, wherein the shield is a part of the outer component.

### Claim 18 (depends on 13)

The cartridge consumable of claim 13, further comprising a swirl ring connected to the outer component via a nozzle of the inner component.

### Claim 19 (depends on 18)

The cartridge consumable of claim 18, further comprising the electrode disposed within a hollow enclosure defined by the swirl ring and the nozzle.

### Claim 20 (depends on 19)

The cartridge consumable of claim 19, wherein at least one of the swirl ring or the electrode is a part of the inner component.

### Claim 21 (depends on 13)

The cartridge consumable of claim 13, further comprising a hollow region between the outer component and the inner component, the hollow region configured to matingly engage a head of the plasma arc torch.

### Claim 22 (depends on 13)

The cartridge consumable of claim 13, further comprising a washer located between the outer component and a nozzle of the inner component, the washer comprising one or more cooling channels configured to regulate a gas flow therethrough.

### Claim 23 (depends on 1)

A method of assembling a multi-piece cartridge consumable comprising an outer component and an inner component for installation into a plasma arc torch, the method comprising:
providing the consumable cartridge of claim 1;
disposing the inner component within a hollow body of the outer component;
axially restraining the outer component relative to a forward portion of the inner component while permitting independent rotation of the inner and outer components relative to each other; and
substantially suspending and radially orienting, by the axial restraining, a rear portion of the inner component within the hollow body of the outer component without the rear portion being in direct physical contact with the hollow body of the outer component.

### Claim 24 (depends on 23)

The method of claim 23, further comprising installing the multi-piece cartridge consumable into a torch head by disposing the torch head in a hollow region between the rear portion of the inner component and the outer component.

### Claim 25 (depends on 24)

The method of claim 24, wherein the installing enables physical mating between a cathode of the torch head and a recess in the rear portion of the inner component.

### Claim 26 (depends on 24)

The method of claim 24, further comprising rotating the outer component independent of the inner component to secure the torch head to the multi-piece cartridge consumable.

### Claim 27 (depends on 23)

The method of claim 23, further comprising assembling the inner component of the multi-piece cartridge including:
disposing an electrode inside of a hollow body of a swirl ring;
retaining the electrode within the hollow body by fixedly securing a nozzle to a distal end of the swirl ring; and
fixedly securing a crown to a proximal end of the swirl ring.

### Claim 28 (depends on 23)

The method of claim 23, further comprising radially aligning the inner component with respect to the outer component by one or more fins disposed on a surface of at least one of the inner or outer component.

### Claim 29 (depends on 23)

The method of claim 23, further comprising assembling the outer component of the multi-piece cartridge including:
over-molding an insulative cap sleeve onto a retaining cap; and
fixedly connecting a shield to the cap sleeve.