Cartridge for a liquid-cooled plasma arc torch

Abstract

A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

What is claimed is: 
     
         1 . A consumable cartridge for a liquid-cooled plasma arc torch, the consumable cartridge comprising:
 a cartridge frame including:
 a body constructed from an electrically insulating material, the body including a central longitudinal axis, a proximal portion and a distal portion; 
 a torch engagement interface surface located at the proximal portion of the body and configured to engage with a torch head to the cartridge, the torch engagement interface comprising at least one fluid opening configured to be substantially aligned with a corresponding opening of the torch head upon engagement between the cartridge and the torch head; and 
 at least one fluid channel disposed in the body and extending between the proximal portion and the distal portion, the at least one fluid channel in communication with the fluid opening on the torch engagement interface; 
   an electrode and a nozzle coupled to the body of the cartridge frame; and   a shield coupled to the distal portion of the body of the cartridge frame and disposed concentrically about the central longitudinal axis.   
     
     
         2 . The consumable cartridge of  claim 1 , wherein the at least one fluid channel comprises a plurality of fluid channels located in the cartridge frame between the proximal portion and the distal portion. 
     
     
         3 . The consumable cartridge of  claim 1 , wherein the consumable cartridge, including the cartridge frame, the electrode, the nozzle and the shield, is replaceable as a single unit 
     
     
         4 . The consumable cartridge of  claim 1 , wherein the electrode is at least partially surrounded by an interior surface of the nozzle. 
     
     
         5 . The consumable cartridge of  claim 1 , further comprising:
 a jacket substantially surrounding the nozzle; and   a coolant flow chamber defined between an exterior surface of the nozzle and an interior surface of the jacket.   
     
     
         6 . The consumable cartridge of  claim 1 , further comprising:
 a liner located between the electrode and the nozzle and disposed within a hollow interior of the nozzle; and   a vent passage cooperatively defined by the nozzle and liner, the vent passage in fluid communication with a vent opening in the cartridge.   
     
     
         7 . The consumable cartridge of  claim 1 , further comprising a swirl ring having a central opening with the electrode disposed therein, wherein the nozzle at least partially surrounds both the electrode and the swirl ring. 
     
     
         8 . The consumable cartridge of  claim 7 , further comprising an electrode insulator located in a hollow interior region of the nozzle and positioned between the electrode and the nozzle to electrically isolate the electrode and the nozzle from each other. 
     
     
         9 . The consumable cartridge of  claim 8 , wherein the electrode, the swirl ring, the electrode insulator and the nozzle are engaged to one another via one of press fit or snap fit. 
     
     
         10 . The consumable cartridge of  claim 1 , wherein the at least one fluid opening includes a·shield gas opening for receiving a shield gas flow from the torch head or a liquid coolant opening for receiving a liquid coolant flow from the torch head. 
     
     
         11 . The consumable cartridge of  claim 2 , wherein the at least one fluid opening includes a plurality of fluid openings for conducting respective ones of a plurality of fluid flows in and out of the cartridge. 
     
     
         12 . The consumable cartridge of  claim 11 , wherein the plurality of fluid openings are in fluid communication with respective ones of the plurality of fluid channels disposed in the cartridge frame, a longitudinal axis of each of the fluid channels being radially offset in relation to the central longitudinal axis of the cartridge frame. 
     
     
         13 . The consumable cartridge of  claim 12 , wherein the plurality of fluid channels comprises at least one of a first fluid channel configured to direct a liquid coolant flow to at least one of the nozzle or shield and a second fluid channel configured to a direct a shield gas flow to the shield. 
     
     
         14 . The consumable cartridge of  claim 12 , wherein the plurality of fluid channels comprises:
 a coolant supply channel, disposed in the body of the cartridge fame, configured to conduct a liquid coolant flow received from the torch head to contact at least one of the nozzle or shield coupled to the cartridge frame; and   a coolant return channel, at least a portion of which disposed in the body of the cartridge frame, configured to conduct at least a portion of the liquid coolant flow from the at least one of the nozzle or shield to the torch head.   
     
     
         15 . The consumable cartridge of  claim 1 , wherein the cartridge frame comprises a central channel disposed about the central longitudinal axis of the cartridge frame, the central channel configured to perform at least one of (i) conduct a fluid flow from the torch head to the electrode or (ii) pass an electrical current from the torch head to the electrode. 
     
     
         16 . The consumable cartridge of  claim 15 , wherein at least a portion of at least one of the electrode or nozzle is disposed in the central channel of the cartridge frame. 
     
     
         17 . The consumable cartridge of  claim 1 , wherein the torch engagement interface surface is configured to radially secure the cartridge to the torch head in a predetermined orientation. 
     
     
         18 . The consumable cartridge of  claim 1 , further comprising a cavity disposed in the proximal portion of the cartridge frame, the cavity configured to house a radio-frequency identification (RFID) tag for communicating with a reader device of the torch head. 
     
     
         19 . The consumable cartridge of  claim 1 , wherein the at least one fluid channel is one of a liquid coolant channel configured to supply a liquid coolant to the nozzle or a gas channel configured to supply a shield gas to the shield. 
     
     
         20 . The consumable cartridge of  claim 1 , wherein a longitudinal axis of the at least one fluid channel is located radially offset relative to the central longitudinal axis of the body of the cartridge frame.