Plasma torch head and method for making the same

A method for forming a head of a plasma torch, the torch head having transfer components for transferring fluids and electric currents, the method comprising the steps of:

• assembling the transfer components of the torch head with respect to each other;
• positioning and securing the assembled transfer components in a core mold;
• filling the core mold with an elastomer;
• curing the elastomer in the core mold, forming an elastic core;
• stripping the elastic core from the core mold;
• and
• forming a shell of a rigid material about the elastic core.

A plasma torch head comprising:

• transfer components for transport of electrical currents and fluid, said transfer components being spaced apart and overlapping in part, forming an overlapping region of said transfer components;
• a core in which a core-supported section of said overlapping region of said transfer components is embedded,
• said core being fabricated from an elastomer so as to be soft and yielding to accommodate thermal expansion and contraction of said transfer components;
• and
• a shell being hard cast material, said shell engaging and housing said core.

A plasma torch head comprising:

• transfer components for transport of electrical currents and fluid, said transfer components being spaced apart and overlapping in part, forming an overlapping region of said transfer components;
• a core in which a core-supported section of said overlapping region of said transfer components is embedded,
• said core being fabricated from an elastomer so as to be soft and yielding to accommodate thermal expansion and contraction of said transfer components;
• and
• a shell molded of a hard material, said shell engaging and housing said core.