Consumable Cartridge for a Plasma Arc Cutting System

Abstract

The invention features a frame for a plasma arc torch cartridge. The frame includes a thermally conductive frame body having a longitudinal axis, a first end configured to connect to a first consumable component, and a second end configured to mate with a second consumable component. The frame body surrounds at least a portion of the second consumable component. The frame also includes a set of flow passages formed within the frame body. The set of flow passages fluidly connects an internal surface of the frame body and an external surface of the frame body. The set of flow holes is configured to impart a fluid flow pattern about the second consumable component.

1 . A plasma arc torch cartridge having an electrode, a nozzle, and a shield, the cartridge further comprising:
 an inner portion relative to a longitudinal axis of the cartridge comprising copper, the inner portion including at least a portion of the shield, the nozzle, and the electrode; and   an outer portion relative to the longitudinal axis, the outer portion at least substantially free of copper, the outer portion surrounding the copper inner portion and including at least a portion of the shield and a portion of the nozzle.   
     
     
         2 . The cartridge of  claim 1  wherein the electrode is a spring electrode. 
     
     
         3 . The cartridge of  claim 1  further including a set of swirl holes, wherein the cartridge cap extends within a base of the nozzle toward the set of swirl holes. 
     
     
         4 . The cartridge of  claim 1  wherein a base of the nozzle is metallic or anodized. 
     
     
         5 . The cartridge of  claim 1  further comprising a retaining cap connected to the cartridge frame. 
     
     
         6 . The cartridge of  claim 5  wherein the retaining cap is formed of a plastic. 
     
     
         7 . The cartridge of  claim 5  wherein the nozzle and the electrode are connected to the retaining cap via a base of the nozzle. 
     
     
         8 . The cartridge of  claim 1  further comprising a shield connected to the cartridge frame. 
     
     
         9 . The cartridge of  claim 8  wherein the shield is connected to the cartridge frame via a shield insulator. 
     
     
         10 . The cartridge of  claim 9  wherein the shield insulator is electrically insulative. 
     
     
         11 . The cartridge of  claim 9  wherein the shield insulator is thermally conductive. 
     
     
         12 . The cartridge of  claim 9  wherein the shield insulator includes anodized aluminum. 
     
     
         13 . The cartridge of  claim 8  wherein the shield has a heat capacity to current ratio of about 2-4 W/m-° K-A. 
     
     
         14 . The cartridge of  claim 1  further including a sleeve disposed about a portion of the electrode. 
     
     
         15 . The cartridge of  claim 14  wherein the sleeve includes an anodized layer formed to electrically isolate the electrode from a base of the nozzle. 
     
     
         16 . The cartridge of  claim 14  wherein the sleeve includes a set of flow surfaces. 
     
     
         17 . The cartridge of  claim 1  further including a cap insert connected to the second end of the cartridge frame, the cap insert substantially orienting the electrode and retaining the electrode within the cartridge frame. 
     
     
         18 . A consumable assembly for a plasma arc torch, the consumable assembly comprising:
 a metallic assembly body extending along a longitudinal axis through the metallic assembly body from a first end to a second end, the metallic assembly body defining a heat sink having a plurality of swirl holes shaped to impart a flow pattern within or around the heat sink;   a nozzle having a base and in physical communication with the first end of the heat sink; and   an electrode disposed within a portion of the heat sink and a portion of the nozzle.   
     
     
         19 . The consumable assembly of  claim 18  wherein the nozzle and the electrode are integrally formed as a part of within a consumable cartridge. 
     
     
         20 . The consumable assembly of  claim 18  wherein the electrode is a spring electrode. 
     
     
         21 . The consumable assembly of  claim 18  further including a cartridge cap, the cartridge cap extending within the base of the nozzle toward the set of swirl holes. 
     
     
         22 . The consumable assembly of  claim 18  wherein the metallic assembly body is anodized. 
     
     
         23 . The consumable assembly of  claim 18  further comprising a retaining cap directly connected to the metallic assembly body. 
     
     
         24 . The consumable assembly of  claim 23  wherein the nozzle and the electrode are connected to the retaining cap via the metallic assembly body. 
     
     
         25 . The consumable assembly of  claim 18  further comprising a shield connected to the metallic assembly body. 
     
     
         26 . The consumable assembly of  claim 25  wherein the shield is connected to the metallic assembly body via a shield insulator. 
     
     
         27 . The consumable assembly of  claim 26  wherein the shield insulator is press fit to at least one of the shield and the base of the nozzle. 
     
     
         28 . The consumable assembly of  claim 26  wherein the shield insulator is electrically insulative. 
     
     
         29 . The consumable assembly of  claim 26  wherein the shield insulator is thermally conductive. 
     
     
         30 . The consumable assembly of  claim 26  wherein the shield insulator includes anodized aluminum. 
     
     
         31 . The consumable assembly of  claim 25  wherein the shield has a heat capacity to current ratio of about 2-4 W/m-° K-A. 
     
     
         32 . The consumable assembly of  claim 18  further including a sleeve disposed about a portion of the electrode. 
     
     
         33 . The consumable assembly of  claim 32  wherein the sleeve includes an anodized layer formed to electrically isolate the electrode from the base of the nozzle. 
     
     
         34 . The consumable assembly of  claim 32  wherein the sleeve includes a set of flow surfaces. 
     
     
         35 . The consumable assembly of  claim 18  further including a cap insert connected to the second end of the metallic assembly body, the cap insert configured to orient the electrode and retain the electrode within the metallic assembly body. 
     
     
         36 . The consumable assembly of  claim 35  further comprising a seal disposed within the cap insert. 
     
     
         37 . A method of cooling a plasma arc torch, the method comprising:
 providing a composite consumable having a heat sink defining a plurality of holes, the composite consumable having integrated components including an electrode, a nozzle and a shield;   installing the composite consumable in the plasma arc torch; and   flowing a cooling fluid through the plurality of holes, the cooling fluid forming a fluid flow pattern that cools at least one of the electrode, nozzle or shield, thereby removing at least one watt of power from the plasma arc torch during operation.