Thermal Torch Lead Line Connection Devices and Related Systems and Methods

A plasma arc torch having at least two fluid lines comprising:

• a torch body defining a first fluid passage and a second fluid passage, the torch body having a proximal end and a distal end;
• a torch consumable mounting location disposed at the distal end of the torch body;
• a lead mounting location disposed at the proximal end;
• a first extension tube coupled to the first fluid passage;
• a second extension tube coupled to the second fluid passage;
• a first connector coupled to the first extension tube, the first connector having an engaged configuration and a disengaged configuration with a corresponding first lead connector;
• and
• a second connector coupled to the second extension tube, the second connector having an engaged configuration and a disengaged configuration with a corresponding second lead connector,
• wherein, in the engaged configuration of the first connector, the first connector is retained within the first lead connector by a locking flange of a locking ring of the first lead connector disposed along a driving lip of the first connector, the locking flange retaining the first connector by a binding region of the first lead connector, and, in the engaged configuration, the first connector provides electrical communication and fluid sealing between the first connector and the first lead connector;
• wherein, in the disengaged configuration of the first connector, the locking flange is offset from the binding region of the first connector and is configured to be displaced by the driving lip of the first connector;
• wherein, in the engaged configuration of the second connector, the second connector is retained within the second lead connector by a locking flange of a locking ring of the second lead connector disposed along a driving lip of the second connector, the locking flange retaining the second connector by a binding region of the second lead connector, and, in the engaged configuration, the second lead connector provides electrical communication and fluid sealing between the second connector and the second lead connector;
• and
• wherein, in the disengaged configuration of the second connector, the locking flange is offset from the binding region of the first connector and is configured to be displaced by the driving lip of the second connector.

A method for electrically and fluidly coupling two conduits that deliver electricity and a fluid from a plasma arc torch control unit to a plasma arc torch, the method comprising:

• translating a male connector defining a first conduit toward a female connector defining a second conduit in an assembly direction;
• engaging an electrical contact connection between the male connector and the female connector;
• mechanically coupling the male and female connectors to create a sealed fluid flow path that limits fluid from exiting a joint between the male and female connectors;
• and
• cooling the electrical contact connection by a fluid flowing through the conduit.

A lead connector for a plasma arc torch for providing an electrical and fluid connection with an adjoining female connector, the lead connector comprising:

• a electrically conductive body defining:
• a fluid passage means configured to receive a fluid from the female connector;
• a means for establishing an electrical connection with a current conducting member disposed within the female connector;
• a means for establishing a fluid connection with a fluid passage of the female connector;
• and
• a means for being retained within the female connector by a locking collar disposed within the female connector.

A method for establishing an electrical connection and a fluid connection between a plasma arc torch and a plasma arc torch control unit, the plasma arc torch control unit having a fluid conduit and the plasma arc torch having a fluid delivery line for providing a fluid to the plasma arc torch, the method comprising:

• inserting a first connector component into a receptacle of a second connector component, the first connector component being inserted a first distance, which is sufficient so that a first substantially cylindrical portion of the first connector component contacts a current conducting member of the second connector component placing the first and second connector components in electrical communication with one another;
• inserting the first connector component into the receptacle an additional, second distance so that a second substantially cylindrical portion of the first connector component contacts a sealing element of the second connector component;
• and
• engaging a resilient, deflectable locking flange of a locking ring in a recess of the first connector component to limit movement of the first connector component away from the second connector component, wherein in an engaged configuration, the first and second connector components are fluidly and electrically connected to one another and together define a fluid flow path for delivering the fluid to the plasma arc torch.