Plasma arc torch cooling system

A plasma arc torch comprising:

• a cathode defining a central bore;
• a coolant tube disposed within the central bore of the cathode;
• a central body disposed within the plasma arc torch, the central body defining angled passages, central axial passages, distal axial passages, and proximal axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• an outer fluid passage formed between the anode shield and the baffle;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip, the electrode defining a central cavity;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum;
• and
• a cooling fluid flows distally through the central bore of the cathode, through coolant tube, flows proximally and into angled passages in the central body, flows distally from the angled passages into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A plasma arc torch comprising:

• a central body disposed within the plasma arc torch, the central body defining distal axial passages and proximal axial passages;
• an anode shield disposed adjacent the central body;
• a baffle disposed adjacent the anode shield;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• and
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum.

A plasma arc torch comprising:

• a central body disposed within the plasma arc torch, the central body defining angled passages and central axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• and
• an outer fluid passage formed between the anode shield and the baffle;
• wherein a cooling fluid flows distally through the angled passages in the central body and into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A plasma arc torch comprising:

• a cathode defining a central bore;
• a coolant tube disposed within the central bore of the cathode;
• a central body disposed within the plasma arc torch, the central body defining angled passages and central axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• and
• an outer fluid passage formed between the anode shield and the baffle;
• wherein a cooling fluid flows distally through the central bore of the cathode, through coolant tube, flows proximally and into angled passages in the central body, flows distally from the angled passages into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A plasma arc torch cutting system comprising:

• a power supply;
• a control system in communication with the power supply;
• and
• a plasma arc torch in communication with the control system, the plasma arc torch comprising:
• a cathode defining a central bore;
• a coolant tube disposed within the central bore of the cathode;
• a central body disposed within the plasma arc torch, the central body defining angled passages, central axial passages, distal axial passages, and proximal axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• an outer fluid passage formed between the anode shield and the baffle;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip, the electrode defining a central cavity;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum;
• and
• a cooling fluid flows distally through the central bore of the cathode, through coolant tube, flows proximally and into angled passages in the central body, flows distally from the angled passages into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A method of operating a plasma arc torch, the method comprising the step of conducting a plasma fluid, a secondary fluid, and a cooling fluid through a plasma arc torch structure comprising:

• a central body disposed within the plasma arc torch, the central body defining angled passages, central axial passages, distal axial passages, and proximal axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• an outer fluid passage formed between the anode shield and the baffle;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum;
• and
• a cooling fluid flows distally through the angled passages in the central body and into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A method of operating a plasma arc torch, the method comprising the step of conducting a plasma fluid, a secondary fluid, and a cooling fluid through a plasma arc torch structure comprising:

• a cathode defining a central bore;
• a coolant tube disposed within the central bore of the cathode;
• a central body disposed within the plasma arc torch, the central body defining angled passages, central axial passages, distal axial passages, and proximal axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• an outer fluid passage formed between the anode shield and the baffle;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip, the electrode defining a central cavity;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum;
• and
• a cooling fluid flows distally through the central bore of the cathode, through coolant tube, flows proximally and into angled passages in the central body, flows distally from the angled passages into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A method of operating a plasma arc torch, the method comprising the step of conducting a cooling fluid through a plasma arc torch structure comprising:

• a central body disposed within the plasma arc torch, the central body defining angled passages and central axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield;
• and
• an outer fluid passage formed between the anode shield and the baffle;
• wherein a cooling fluid flows distally through the angled passages in the central body and into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A method of operating a plasma arc torch cutting system, the method comprising the steps of:

• operating a power supply;
• operating a control system in communication with the power supply;
• and
• conducting a plasma fluid, a secondary fluid, and a cooling fluid through a plasma arc torch structure comprising:
• a cathode defining a central bore;
• a coolant tube disposed within the central bore of the cathode;
• a central body disposed within the plasma arc torch, the central body defining angled passages, central axial passages, distal axial passages, and proximal axial passages;
• an anode shield disposed adjacent the central body;
• an inner cooling chamber formed between the central body and the anode shield;
• a baffle disposed adjacent the anode shield
• an outer fluid passage formed between the anode shield and the baffle;
• a shield cap disposed adjacent the baffle;
• a secondary fluid passage formed between the baffle and the shield cap;
• a tip disposed in a distal portion of the central body;
• an electrode disposed adjacent the tip, the electrode defining a central cavity;
• a plasma chamber formed between the tip and the electrode;
• a secondary orifice disposed adjacent the tip;
• and
• a secondary fluid plenum formed between the tip and the secondary orifice, wherein,
• a plasma fluid flows distally through the distal axial passages in the central body and into the plasma chamber;
• a secondary fluid flows distally through the proximal axial passages in the central body, into the secondary fluid passage, and into the secondary fluid plenum;
• and
• a cooling fluid flows distally through the central bore of the cathode, through coolant tube, flows proximally and into angled passages in the central body, flows distally from the angled passages into the inner cooling chamber, and flows proximally through the outer fluid passage and through the central axial passages.

A method of operating a plasma arc torch comprising the steps of:

• conducting a plasma fluid coaxially through a structure of the plasma arc torch;
• conducting a secondary fluid coaxially through the structure of the plasma arc torch;
• and
• conducting a cooling liquid coaxially through the structure of the plasma arc torch, wherein the cooling liquid flows distally and proximally through the structure.