TORCH EQUIPMENT

PRIORITY

[01] The present application claims priority to U.S. Provisional Patent Application

No. 61/943,594 and US Patent Application 14/625,286 filed February 18, 2015, which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

[02] Devices, systems, and methods consistent with the invention relate to cutting, and more specifically to devices, systems and methods for aligning and securing components of a plasma arc torch. More particularly, the invention provides a nozzle assembly for torch and a torch assembly according to the preamble of claim 1 and 23, respectively.

BACKGROUND

[03] In many cutting, spraying and welding operations, plasma arc torches are utilized. With these torches, a plasma gas jet is emitted into the ambient atmosphere at a high temperature. The jets are emitted from a nozzle and, as they leave the nozzle, the jets are highly under-expanded and very focused. However, as the jet leaves the nozzle it begins to expand rapidly. This expansion can greatly reduce the efficiency of the nozzle as the jet energy is lost in the jet expansion, and thus there is a loss of jet thrust and focus. In applications, such as cutting and welding, this expansion can diminish the quality and process speeds, especially in cutting operations. Further, the shape of the nozzle throat can cause arc instability, which further diminishes performance. Therefore, improved nozzle performance is desirable.

[04] Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such approaches with embodiments of the present invention as set forth in the remainder of the present application with reference to the drawings.

BRIEF SUMMARY OF THE INVENTION

[05] An exemplary embodiment of the present invention is a plasma torch nozzle and torch utilizing the nozzle, where the nozzle has a configuration which stabilizes and optimizes the plasma arc for improved performance.

[06] In an exemplary embodiment of the invention, a nozzle assembly includes an upper portion defining an opening for receiving a gas and a longitudinally extending cylindrical body portion adjacent to the upper portion and defining a passageway for the gas. The nozzle assembly also includes a tip portion adjacent to the body portion, with the tip portion defining a throat channel. The throat channel includes a throat inlet region that focuses a flow of the gas. The throat inlet region is fluidly connected to the passageway via a throat inlet opening. The throat channel also includes an acceleration region that is disposed downstream of the throat inlet region and fluidly connected to the throat inlet region to compress the gas and accelerate the flow of the gas. The throat channel further includes an expansion region disposed downstream of the acceleration region and fluidly connected to the acceleration region to allow the gas to expand. The expansion region includes a throat outlet opening through which the gas exits the nozzle assembly.

[07] In another exemplary embodiment a torch assembly used in cutting, spraying and/or welding operations includes an electrode and a swirl ring for receiving a gas. The torch assembly also includes a nozzle. The nozzle includes an upper portion defining an opening for receiving a portion of the electrode and a portion of the swirl ring such that an annular channel is formed to receive the gas. The nozzle also includes a longitudinally extending cylindrical body portion adjacent to the upper portion that extends the annular channel for the gas and a tip portion adjacent to the body portion that defines a throat channel. The throat channel includes a throat inlet region to focus a flow of the gas, the throat inlet region being fluidly connected to the passageway via a throat inlet opening. The throat channel also includes an acceleration region disposed downstream of the throat inlet region and fluidly connected to the throat inlet region to compress the gas and accelerate the flow of the gas. The throat channel further includes an expansion region disposed downstream of the acceleration region and fluidly connected to the acceleration region to allow the gas to expand. The expansion region includes a throat outlet opening through which the gas exits the nozzle assembly. Further embodiments, features and aspects of the invention are inferable from the ensueing description, drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[08] The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:

[09] FIG. 1 is a perspective view of one example of a plasma arc torch system according to certain aspects of the disclosure;

[10] FIG. 2 is a perspective view of the torch portion of the system of FIG. 1 ;

[11] FIG. 3 is an exploded perspective view of the end of the torch portion of FIG.

2;

[12] FIG. 4 is a cross-sectional view of the electrode and nozzle portion of the torch of FIG. 2;

[13] FIG. 5 is a diagrammatical representation of a plasma jet as it exits a known torch nozzle configuration; [14] FIG. 6 is a diagrammatical representation of a plasma jet as it is projected from an electrode to a nozzle of a known configuration;

[15] FIG. 7 is a cross-section of an exemplary embodiment of a nozzle end portion and an electrode; and

[16] FIG. 8 is a cross-sectional close-up view of a throat portion at the end of the nozzle shown in FIG. 7.

DETAILED DESCRIPTION

[17] Reference will now be made in detail to various and alternative exemplary embodiments and to the accompanying drawings, with like numerals representing substantially identical structural elements. Each example is provided by way of explanation, and not as a limitation. In fact, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the scope or spirit of the disclosure and claims. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure includes modifications and variations as come within the scope of the appended claims and their equivalents.

[18] The present disclosure is generally directed to nozzle and nozzle throat configurations for a plasma arc torch that can be useful in various cutting, welding and spraying operations. It should be noted that for purposes of brevity and clarity, the following discussion will be directed to exemplary embodiments of the present invention which are primarily directed to a plasma torch for cutting. However, embodiments of the present invention are not limited in this regard and embodiments of the present invention can be used in welding and spraying torches without departing from the spirit or scope of the present invention. The application of the present invention can include use in either mechanized torch assemblies or hand-held torch assemblies. Various types and sizes of torches are possible at varying voltages if desired. Further, the torches using the disclosed nozzles could be used for marking, cutting or metal removal. Additionally, exemplary embodiments of the present invention, can be used with varying currents and varying power levels. Of course, it should also be noted that embodiments of the present invention can be used in torches which are cooled with a torch coolant. The construction and utilization of such coolant systems are known and need not be discussed in detail herein.

[19] FIG. 1 shows one example of such a plasma arc torch device 10. As shown, device 10 includes a housing 12 with a connected torch assembly 14. Housing 12 includes the various conventional components for controlling a plasma arc torch, such as a power supply, a plasma starting circuit, air regulators, fuses, transistors, input and output electrical and gas connectors, controllers and circuit boards, etc. Torch assembly 14 is attached to a front side 16 of housing 12. Torch assembly 14 includes within it electrical connectors to connect an electrode and a nozzle within the torch end 18 to electrical connectors within housing 12. Separate electrical pathways may be provided for a pilot arc and a working arc, with switching elements provided within housing 12. A gas conduit is also present within torch assembly to transfer the gas that becomes the plasma arc to the torch tip, as will be discussed later. Various user input devices 20 such as buttons, switches and/or dials may be provided on housing 12, along with various electrical and gas connectors.

[20] It should be understood that the housing 12 illustrated in FIG. 1 is but a single example of a plasma arc torch device that could employ aspects of the inventive the concepts disclosed herein. Accordingly, the general disclosure and description above should not be considered limiting in any way as to the types or sizes of plasma arc torch devices that could employ the disclosed torch elements.

[21] As shown in FIG. 1 , torch assembly 14 includes a connector 22 at one end for attaching to a mating connector 23 of housing 12. When connected in such way, the various electrical and gas passageways through the hose portion 24 of torch assembly 14 are connected so as to place the relevant portions of torch body 26 in connection with the relevant portions within housing 12.

[22] FIG. 3 shows an exploded view of the end of torch body 26. As shown therein, attached to torch body 26 are electrode 28, swirl ring 30, nozzle 32, retaining cap 34, and shield cap 36. First mating threads 38 and 40 on torch body 26 and retaining cap 34, and second mating threads 42 and 44 on retaining cap 34 and shield cap 36 may be used to hold these pieces together on the end of torch body 26 in the configuration shown in FIG. 2. The sizes, dimensions and arrangements of these elements may be varied somewhat depending on the desired amperage, flow, work to be performed, etc. as is conventional, and additional parts may be employed in some arrangements depending on the application.

[23] FIG. 4 shows an enlarged cross section of an electrode 28, swirl ring 30 and nozzle 32 according to certain aspects of the invention. For clarity in FIG. 4, other elements of torch body 26 are not shown.

[24] As shown, nozzle 32 includes an upper annular seating section 46 with an annular inner opening 48 for receiving a portion of swirl ring 30 and an outer annular shoulder 49 for contacting an inner portion of retaining cap 34 (not shown in FIG. 4). Nozzle 32 further includes along its outside a longitudinally extending body portion 50 and a tapered portion 52 ending in a flat tip 54. Within nozzle 32 is defined a passageway including a cylindrical portion 56, a tapered portion 58, a transition area 60 and a reduced diameter outlet passage 62 exiting nozzle 32 via flat tip 54. [25] Electrode 28 is a substantially cylindrical body. Flange 64 is provided to position electrode 28 for mounting in torch body 26 and to position the electrode relative to swirl ring 30 and nozzle 32 once all are assembled together, and threads (not shown) may be provided to assist in assembly of electrode 28 to torch body 26. A central cylindrical portion 66 of electrode 28 ends at a tapered portion 68, which faces tapered portion 58 of nozzle 32 once assembled together. A distal end face 70 of electrode 28 is located opposite outlet passage 62. A small curved portion 67 may be present between cylindrical portion 66 and tapered portion 68 as a smoothing transition, if desired.

[26] In use, gas flows inwardly through passages 72 within swirl ring 30, down the passageway formed between cylindrical portion 56 of nozzle 32 and cylindrical portion 66 of electrode 28 and the two tapered portions 58 and 68 to and through outlet passage 62. Suitable conventional seal members (not shown) may be provided as desired between torch body 26, electrode 28, swirl ring 30, nozzle 32, retaining cap 34, and/or shield cap 36, etc. to confine gas flow to desired passageways and prevent leakage through interfaces, threaded areas, etc.

[27] End face 70 of electrode 28 has a discontinuous surface. Tapered portion

68 includes a discontinuity, in this case an annular edge 74. In the embodiment as shown in FIG. 4, annular edge 74 is the most distal portion of electrode 28, although it should be understood that the annular edge need not be the most distal portion.

[28] Nozzle tapered portion 58 may be at the same angle or a different angle than tapered portion 68 with reference to longitudinal axis 82. As shown, tapered portion 68 is at a slightly different angle than tapered portion 58, so that the space between electrode 28 and nozzle 32 decreases slightly in the distal direction (toward outlet passage 62). [29] A number of variations to the above elements are possible, in particular to electrode 28. In the additional embodiments below, like or similar reference numerals refer to like or similar parts.

[30] Turning now to Figure 5, an arc plasma is shown exiting the related art outlet passage 62 of a typical nozzle 32. As shown, immediately after the arc plasma jet leaves the passage 62, it begins to expand rapidly which can diminish the performance and effectiveness of the plasma. This is particular true in cutting operations. Further, as shown in Figure 6, in many instances the arc created by the electrode 28 can contact the side walls of the related art outlet passage 62 in the nozzle 32 which further aids in destabilizing the plasma jet as it leaves the nozzle. Embodiments of the present invention significantly improve in the performance of the plasma jet and torch assembly overall. This is discussed further below.

[31] Figure 7 depicts an exemplary embodiment of the present invention, where only the electrode 28 and nozzle 32 of a torch assembly is shown. As stated previously, embodiments of the present invention are not limited to being used in only cutting operations, but can also be used in spraying and welding operations. As shown, embodiments of the present invention, use a particular nozzle throat 100 (or outlet passage) configuration as shown. The nozzle throat 100 has an inlet 102 which is positioned adjacent to the distal end of the electrode 32 when assembled, and an outlet 106 through which the plasma jet leaves the nozzle 32. Further, the throat 100 is defined by three throat sections. The upstream most section is the throat inlet region 101 , which is followed by the acceleration region 103, and then the downstream most region is the expansion region 105. The interaction of these regions with the plasma jet as it passes through the throat 100 provides for an optimized and focused plasma jet that minimizes its expansion after it leaves the nozzle 32, as well as providing a throat 100 which aids in minimizing the contact between the arc and the sidewalls of the throat 100. Further discussion of the throat 100 is discussed below with respect to Figure 8.

[32] Figure 8 shows more detail of the nozzle throat 100 of the present invention.

As stated earlier, the upstream most section of the throat 100 is the throat inlet region 101. The throat inlet region generally has a generally tapered profile from the inlet 102 to the transition 114 between the inlet region 101 to the acceleration region 103. Typically, the inlet 102 has a diameter that is in the range of 0.015 to 0.65 in, and is in the range of 30 to 400% larger than that of the diameter of the acceleration region 103. As shown, the acceleration region 103 has a constant diameter from the upstream transition 114 to the downstream transition 116 between the acceleration region 103 and the expansion region 105, and the diameter of the acceleration region in is in the range of 0.015 to 0.5 in. The expansion region 105 has a generally tapered profile as shown where the diameter of the outlet 106 is larger than that of the diameter of the acceleration region 103. In exemplary embodiments of the present invention, the outlet 106 has a diameter in the range of 0.015 to 0.65 in, and can be in the range of 5 to 50% larger than the diameter of the acceleration region 103.

[33] In exemplary embodiments, the length of the inlet region 101 is in the range of 5 to 30% of the thickness of the nozzle 32 at the throat. The acceleration region 103 is in the range of 30 to 85% of the thickness of the nozzle 32 at the throat and the expansion region 105 is in the range of 5 to 85% of the thickness of the nozzle 32 at the throat.

[34] With this configuration, the inlet region 101 stabilizes the plasma jet as it enters the throat 100 from the electrode 28. This aids in preventing the plasma from inadvertently contacting the side walls of the throat and helps to focus the plasma jet. As the jet enters the acceleration region 103 the jet is compressed by the side walls and the flow of the jet is accelerated. When the jet passes from the acceleration region 103 to the expansion region 105, the plasma jet is allowed to expand. However, the expansion is controlled by the sidewalis of the expansion region 105 such that as the jet leaves the outlet 106 it does not rapidly expand like when using prior known nozzles. The expansion is less drastic and thus provides a more focused and controller plasma jet. Thus, embodiments of the present result in the creation of more accurate cuts (when used in a cutting application).

[35] Also, as shown in Figure 8, in some exemplary embodiments, each of the inlet region 101 and the expansion region 105 can have distinct portions to aid in optimizing the flow of plasma jet as it passes through the throat 100. As shown, in some exemplary embodiments, the inlet region 101 has three distinct portions - a first or inlet portion 1 11 , a transition portion 113, and a focus portion 15. Similarly, in some exemplary embodiments, the expansion region 105 has an expansion portion 151 and a stabilization portion 153.

[36] In the inlet region 101 , the inlet portion 1 1 1 has a tapered wall surface as shown. This surface aids in ensure that the plasma jet properly enters the throat and begins to focus the jet to the center of the throat. In exemplary embodiments, the inlet portion 1 11 has an angled wall surface that is angled (c ) in the range of 45 to 75 degrees, with respect to the centerline of the throat 100. Further, the length of the inlet portion 1 11 (along the centerline) is in the range of 10 to 60 % of the length of the inlet region 101. Following the inlet portion 111 is the transition portion 1 13 which permits the jet to stabilize briefly after it enters throat 100. In exemplary embodiments of the present invention, the angling of the inlet portion 11 1 is not steeper than that of the focus portion 1 15 (i.e., a ₂ value is lower than α-ι value), and thus the transition portion 1 13 aids in stabilizing the plasma prior to be more fully focused in the focus portion 1 15. In the embodiment shown, the transition portion 113 has a constant diameter along its length. However, in other exemplary embodiments, the transition portion 113 can also have an angled or an arcuate surface to allow for a transition from the inlet portion to the focus portion 115 of the inlet region 101. In exemplary embodiments, the transition portion 113 has a length in the range of 20 to 80 % of the length of the inlet region 101. The focus portion 115 focuses and compresses the plasma jet before it enters the acceleration portion 103 of the throat 100. As shown, in exemplary embodiments the focus portion 115 is the longest portion of the inlet region 101 and has an angled surface. The angle (a ₂ ) of the surface is in the range of 30 to 55 degrees with respect to the centerline of the throat and typically has a shallower angle than inlet portion 111. Further, in some embodiments, the length of the focus portion 115 is in the range of 5 to 95 % of the length of the inlet region 101. In some embodiments, the length of the focus portion 115 is in the range of 10 to 90 % of the length of the inlet region 101. In the embodiment shown, the angle of the surface of the focus portion 115 is constant from the transition portion 113 to the transition 114. However, in other exemplary embodiments, the focus portion 115 can use at least two different angles between the transition portion 113 and the transition 114.

[37] Also as shown in Figure 8, the expansion region 105 has an expansion portion 151 which has an angled surface that expands as it goes toward the outlet 106. This portion allows the jet to expand in a controlled manner. In exemplary embodiments, the wall of the expansion portion 151 is angled at an angle (a ₃ ) in the range of 2 to 30 degrees, relative to the centerline of the throat, and a length in the range of 5 to 95 % of the length of the expansion portion 105. Downstream of the expansion portion 151 is a stabilization portion 153 which stabilizes the plasma jet after it has been expanded. This stabilization portion allows the jet to exit the outlet 106 in a more focused state as compared to known nozzles and prevents the over-expansion of the jet prior to the workpiece. More specifically, the stabilization portion allows the jet to be perfectly expanded for various cutting opera- tions. In the embodiment shown in Figure 8, the diameter of the stabilization portion has a constant diameter along its length. However, in other exemplary embodiments, the wall of the stabilization portion can be angled, and can be angled either toward or away from the centerline. However, in either case, to the extent the wall is angled in the stabilization portion, the angle is less than the angle of the wall in the expansion portion 151. Further, in exemplary embodiments, the outlet 106 has a diameter which is less than that of the inlet 102. In exemplary embodiments, the outlet 106 has a diameter in the range of 10 to 50 % of the diameter of the acceleration region 103.

[38] In further exemplary embodiments, the nozzle 32 can be constructed from a plurality of components that - when coupled together - created a nozzle assembly similar in construction to the nozzle 32 described above and shown in the Figures. In such embodiments, each of the separate nozzle components include portions of the throat 100, such that when the components are assembled they formed a completed throat 100. For example, in some embodiments, the nozzle 32 can be made of three separate components, such that when they are coupled together they form the throat 100. In such an embodiment, an inner nozzle portion contains only the inlet region 101 , an intermediate nozzle portion contains only the acceleration region 103, and an outer nozzle portion contains only the expansion region 105. When these separate and distinct nozzle components are assembled, they form the completed nozzle assembly (similar to 32) and have the entire throat 100. They can be assembled via any known methodology, including screwing each of the nozzle portions to each other via threads. Other connection means can also be used. When assembled there gaps between the separate components should be small so as to ensure optimum performance of the throat 100. Such embodiments allow a user to only replace a portion of the nozzle assembly that may be damaged, without having to replace the other nozzle components. Further, embodiments such as these allow a user to couple different throat geometries as needed. That is, a user can have a plurality of each of the inner, intermediate and outer nozzle portions - each having differing dimensions for their respect throat regions. With this, a user can assemble a custom nozzle assembly having an optimized throat configuration for a given cutting operation. That is, a user can create a custom nozzle and throat for a given operation. Further, in other exemplary embodiments, the nozzle 32 can be made from two separate and distinct components where one of the nozzle components contains two out of the three regions described above, while the other contains the other region. For example, a first nozzle portion contains the inlet and acceleration regions 101/103, and the other nozzle portion contains the expansion region 105. This configuration can allow a user to, again, assembly various nozzle components to achieve a customized throat 100 for a desired plasma jet configuration. Further, this can allow a user to replace only a portion of the nozzle, if only that portion was damaged.

[39] It should be noted that in some exemplary embodiments of the present invention, the torch, nozzle and electrode are constructed such that the distance or gap between electrode and nozzle can be adjusted. This adjustment allows a user to obtain a desired plasma jet performance and configuration. For example, a screw type connection can be used to adjust the distance between these components. Thus, in use a user can adjust this distance prior to cutting.

[40] With the embodiments described herein an optimized nozzle and throat configuration can be attained for a particular function. That is, with embodiments of the present invention, a plasma jet can be created at a desired velocity and focus for a particular operation. Because of this, performance and precision levels can be achieved that cannot be achieved by known nozzle configurations. [41] In one embodiment, the invention provides ai nozzle assembly includes an upper portion defining an opening for receiving a gas and a longitudinally extending cylindrical body portion adjacent to the upper portion and defining a passageway for the gas. The nozzle assembly also includes a tip portion adjacent to the body portion, with the tip portion defining a throat channel. The throat channel includes a throat inlet region that focuses a flow of the gas. The throat inlet region is fluidly connected to the passageway via a throat inlet opening. The throat channel also includes an acceleration region that is disposed downstream of the throat inlet region and fluidly connected to the throat inlet region to compress the gas and accelerate the flow of the gas. The throat channel further includes an expansion region disposed downstream of the acceleration region and fluidly connected to the acceleration region to allow the gas to expand.

[42] While the claimed subject matter of the present application has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claimed subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the claimed subject matter without departing from its scope. Therefore, it is intended that the claimed subject matter not be limited to the particular embodiment disclosed, but that the claimed subject matter will include all embodiments falling within the scope of the appended claims.

Reference Numbers

torch device

housing

connected torch assembly

front side

mating connector

hose portion

torch body

electrode

swirl ring

nozzle

retaining cap

second mating thread

second mating thread

seating section

annular inner opening

outer annular shoulder

extending body portion

tapered portion

flat tip

cylindrical portion

tapered portion

transition area

reduced diameter outlet passage

central cylindrical portion

small curved portion

tapered portion

distal end face

passages

annular edge

longitudinal axis

throat

throat inlet region

acceleration region

expansion region

first or inlet portion

transition portion

focus portion

expansion portion

stabilization portion