Plasma torch

Claim 2

A front-end assembly for a plasma arc torch utilizing a single inlet gas for both plasma and secondary gas, comprising: a. subassembly including a tip element with integral swirl ring said subassembly being removable from said plasma arc torch; b. an electrode having an integral hollow elongated interior cooling tube, said electrode nesting in said subassembly; c. a nozzle, said subassembly nesting in said nozzle; and d. means for releasably mounting said nozzle on said torch, said subassembly nesting in said nozzle, and said electrode nesting in said subassembly when said nozzle is mounted on said torch.

Claim 3

The apparatus of claim 1 wherein said electrode includes: a. an elongated outer tube having a first open end and a second closed end; b. said integral hollow elongated interior cooling tube sized to fit inside of said outer tube forming an annular conduit between said interior cooling tube and said outer tube, said interior cooling tube having a first end and a second end, said first end of said interior cooling tube engaging and sealing with said first open end of said outer tube; and c. a radial shoulder positioned on the exterior of said outer tube, said shoulder having at least one port therein perforating said outer tube and allowing said inlet gas to pass from said annular conduit through said port to the exterior of said electrode.

Claim 4

The apparatus of claim 2 wherein said subassembly including said tip element with swirl ring includes: a. a hollow generally cylindrical electrically non-conductive body sized to allow said electrode to pass through said hollow body, said hollow body having a larger diameter than said electrode to create an annular passageway for passage of said inlet gas; b. a plurality of longitudinally aligned channels in the exterior of said body for passage of said inlet gas; c. said hollow body having a first end and a second end; and d. said first end abutting said shoulder of said electrode and said first end forming a plurality of tangentially aligned slots causing said gas to swirl in said annular passageway, after it passes through said slots.

Claim 5

The apparatus of claim 3 wherein said tip element further includes: a. an electrically conductive barrel forming a first open end and a second closed end having a blunt terminus; b. a shoulder on said barrel positioned between said first end and said second end; c. said first end forming a recess sized to enclose a portion of said electrode, said recess having a larger diameter than said electrode to extend said annular passageway for said inlet gas; d. an orifice in said blunt terminus allowing said inlet gas to pass from said annular passageway through said orifice as plasma to the exterior of said tip element; and e. a barb positioned on said first open end of said barrel for engaging said swirl ring to create an integral element.

Claim 6

The apparatus of claim 4 wherein said nozzle includes: a. a central aperture sized to permit said tip to pass through said aperture and extend beyond said nozzle; and b. a plurality of grooves adjacent said central aperture allowing said secondary gas to contact said tip for cooling of said tip and allowing said secondary gas to exit said torch in an envelope about said plasma.

Claim 7

The apparatus of claim 5 wherein said electrode has an electrically conductive insert positioned in said second closed end of said electrode.

Claim 8

The apparatus of claim 6 wherein said electrode is formed from an electrically conductive material.

Claim 9

The apparatus of claim 7 wherein said electrically conductive material is a copper alloy and said insert hafnium.

Claim 10

The apparatus of claim 5 wherein said nozzle further includes an inner basket of electrically conductive material in electrical contact with the electrical supply of the pilot arc to initially start the arc in said torch.

Claim 11

The apparatus of claim 9 wherein said means for releasably mounting said nozzle is a series of threads in said inner basket sized to mate and engage with a series of threads as on the surface on said torch.

Claim 12

The apparatus of claim 9 wherein said swirl ring is plastic and said tip is a copper alloy.

Claim 13

The apparatus of claim 2 wherein said cooling tube extends substantially the entire length of said integral electrode inside of said outer tube for cooling of said insert.

Claim 14

A removably elongated electrode for use in a plasma arc torch, said torch further including an electrically conductive seat, a trigger assembly, a compressed air source, a subassembly including a tip element with integral swirl ring and a nozzle comprising: a. a elongated outer tube having a first open end and a second closed end; b. an integral hollow elongated interior cooling tube sized to fit inside of said outer tube forming an annular conduit between said interior cooling tube and said outer tube, said interior cooling tube having a first end and a second end, said first end of said interior cooling tube engaging and sealing with said first open end of said outer tube; c. a radial shoulder positioned on the exterior of said outer tube, said shoulder having at least one port therein perforating said outer tube, said port in communication with said annular conduit; and d. said radial shoulder engaging an electrically conductive seat when said electrode is assembled with said subassembly and said nozzle; and e. said radial shoulder being blown out of engagement with said conductive seat by said compressed air source when said trigger is engaged and said electrode is assembled with said nozzle.

Claim 15

A removably elongated electrode for use in a plasma arc torch, said torch further including an electrically conductive seat, a trigger assembly, a compressed air source, a subassembly including a tip element with integral swirl ring and a nozzle comprising: a. a elongated outer tube having a first open end and a second closed end; b. an integral hollow elongated interior cooling tube sized to fit inside of said outer tube forming an annular conduit between said interior cooling tube and said outer tube, said interior cooling tube having a first end and a second end, said first end of said interior cooling tube engaging and sealing with said first open end of said outer tube; c. a radial shoulder positioned on the exterior of said outer tube, said shoulder having at least one port therein perforating said outer tube, said port in communication with said annular conduit; and d. said radial shoulder engaging an electrically conductive seat when said electrode is assembled with said subassembly and said nozzle; and e. said radial shoulder being blown out of engagement with said conductive seat by said compressed air source when said trigger is engaged and said electrode is assembled with said nozzle.

Claim 16

The apparatus of claim 13 wherein said integral electrode includes: a. said first open end of said elongated outer tube forming an interior circumferential journal. b. said first end of said integral cooling tube forming an exterior circumferential shoulder sized to seal and engage with said interior journal.

Claim 17

The apparatus of claim 14 wherein said cooling tube extends substantially the entire length of said integral electrode inside of said outer tube for cooling said insert.

Claim 18

The apparatus of claim 15 wherein said electrode has an electrically conductive insert positioned in said second closed end of said electrode.

Claim 19

The apparatus of claim 16 wherein said electrode is a copper alloy and said insert is hafnium.

Claim 20

A removable subassembly including a tip element with integral swirl ring for use in a plasma arc torch employing an elongate electrode, and an inlet gas, said integral swirl ring including: a. a hollow generally cylindrical electrically nonconductive body sized to allow said electrode to pass through said hollow body, said hollow body having a larger diameter than said electrode to create an annular passageway for passage of said inlet gas; b. a plurality of longitudinally aligned channels in the exterior of said body for passage of said inlet gas; c. said hollow body having a first end and a second end; and d. said first end abutting said shoulder of said electrode and said first end forming a plurality of tangentially aligned slots causing said gas to swirl in said annular passageway, after it passes through said slots.

Claim 21

A removable subassembly including a tip element with integral swirl ring for use in a plasma arc torch employing an elongate electrode, and an inlet gas, said integral swirl ring including: a. a hollow generally cylindrical electrically nonconductive body sized to allow said electrode to pass through said hollow body, said hollow body having a larger diameter than said electrode to create an annular passageway for passage of said inlet gas; b. a plurality of longitudinally aligned channels in the exterior of said body for passage of said inlet gas; c. said hollow body having a first end and a second end; and d. said first end abutting said shoulder of said electrode and said first end forming a plurality of tangentially aligned slots causing said gas to swirl in said annular passageway, after it passes through said slots.

Claim 22

The apparatus of claim 17 wherein said tip element further includes: a. an electrically conductive barrel forming a first open end and a second closed end having a blunt terminus; b. a shoulder on said barrel positioned between said first end and said second end; c. said first end forming a recess sized to enclose a portion of said electrode, said recess having a larger diameter than said electrode to extend said annular passageway for said inlet gas; d. an orifice in said blunt terminus allowing said inlet gas to pass from said annular passageway through said orifice as plasma to the exterior of said tip element; and e. a barb positioned on said first open end of said barrel for engaging said swirl ring to create an integral element.