US Pat. No. 9,148,943

THERMAL TORCH LEAD LINE CONNECTION DEVICES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A lead connector assembly for a plasma arc torch for providing electrical and fluid connections between a male lead connector
and a female lead connector disposed in association with a plasma arc torch power supply, wherein the female lead connector
comprises a current conductive member, a sealing member, clearance region, binding region, and a locking ring having a locking
flange, the male lead connector comprising:
a body defining an internal fluid passage, an electrical contact region, a sealing region, a locking trough, and a driving
lip, the male lead connector, when assembled to the female lead connector, having an engaged configuration and a disengaged
configuration,

wherein, in the engaged configuration, the electrical contact region forms an electrical connection with the current conducting
member, the sealing region forms a seal against the sealing member, the locking trough receives the locking flange, and the
locking flange is positioned between the driving lip and the binding region, and, as a result of the engaged configuration,
the male lead connector is locked within the female lead connector.

US Pat. No. 9,510,436

WIDE BANDGAP SEMICONDUCTOR BASED POWER SUPPLY ASSEMBLIES FOR PLASMA OPERATING SYSTEMS AND RELATED METHODS AND DEVICES

Hypertherm, Inc., Hanove...

1. A plasma torch cutting system comprising:
a housing; and
a plasma torch power supply within the housing and configured to generate a signal that initiates generation of a plasma arc
in a torch head, the power supply including an integrated output circuit configured to receive a signal from an input circuit
of the power supply and generate the signal that initiates generation of the plasma arc, the integrated output circuit comprising
a plurality of electronic components, at least one of the electronic components of the integrated output circuit being at
least partially formed of a wide bandgap semiconductor material,

a ratio of a level of nominal power generated by the power supply to a combined weight of the housing, the power supply, and
any other components contained within or coupled to the housing being at least 800 Watts per kilogram (W/kg).

US Pat. No. 9,107,282

ASYMMETRIC CONSUMABLES FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A consumable set usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece, the consumable
set comprising:
a nozzle including: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice, disposed
in the nozzle body, for constricting the plasma arc, wherein the nozzle exit orifice defines an exit orifice axis oriented
at a non-zero angle relative to the longitudinal axis; and

an alignment surface generally parallel to the exit orifice axis, the alignment surface being dimensioned to align the exit
orifice such that the plasma arc impinges orthogonally on the processing surface of the workpiece, wherein (i) the alignment
surface is configured to lay at least substantially flush against a guiding surface angled relative to the processing surface
of the workpiece and (ii) the longitudinal axis of the nozzle body is oriented at an acute angle relative to the alignment
surface.

US Pat. No. 9,144,148

DEVICES FOR GAS COOLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A nozzle for a gas-cooled plasma arc torch, the nozzle comprising:
a hollow generally cylindrical body having a first end and a second end that define a longitudinal axis, the second end of
the body defining a nozzle exit orifice;

a gas channel formed in the first end between an interior wall and an exterior wall of the cylindrical body, the gas channel
directing a gas flow circumferentially about at least a portion of the body;

an inlet passage formed substantially through a radial surface of the exterior wall and fluidly connected to the gas channel,
the inlet passage defining an inlet port formed through the radial surface of the exterior wall; and

an outlet passage at least substantially aligned with the longitudinal axis and fluidly connected to the gas channel, the
outlet passage defining an outlet port formed through a second exterior radial surface of the body between the second end
of the nozzle and the inlet port.

US Pat. No. 9,736,918

ELECTRODE FOR A CONTACT START PLASMA ARC TORCH AND CONTACT START PLASMA ARC TORCH EMPLOYING SUCH ELECTRODES

Hypertherm, Inc., Hanove...

1. A swirl ring component of a contact start plasma arc torch, the swirl ring component comprising:
a hollow body formed of a front portion and a rear portion along a longitudinal axis and defining an exterior surface and
an interior surface;

one or more gas passageways extending from the exterior surface to the interior surface in the front portion of the hollow
body;

a resilient element including a spring and a separate contact surface comprising an annular, washer-like plate secured to
the spring, the resilient element disposed relative to the interior surface in the rear portion of the hollow body and configured
to pass at least a pilot arc current to an electrode body, wherein the separate contact surface of the resilient element is
configured to facilitate physical contact with a proximal portion of the electrode body; and

a shoulder portion configured to retain the resilient element in the hollow body.

US Pat. No. 9,144,882

IDENTIFYING LIQUID JET CUTTING SYSTEM COMPONENTS

Hypertherm, Inc., Hanove...

1. A liquid jet cutting system, comprising:
at least one reader;
a pump;
a cutting head fluidly connected to the pump, the cutting head comprising:
a cutting head body;
a plurality of replaceable components connected to the cutting head body and defining at least a portion of a conduit for
receiving a liquid jet;

a plurality of signal devices assigned to respective ones of the plurality of replaceable components, wherein the plurality
of signal devices are configured to communicate to the at least one reader information associated with the corresponding replaceable
components;

a plurality of readers disposed on the cutting head body for communicating with the plurality of signal devices about the
information associated with the corresponding replaceable components; and

a connector communicatively coupled to the plurality of readers, the connector being configured to transmit the information
from the plurality of readers to a CNC or a PLC; and

a computing device communicatively coupled to the at least one reader for receiving the information from the reader.

US Pat. No. 9,481,050

PLASMA ARC CUTTING SYSTEM AND PERSONA SELECTION PROCESS

Hypertherm, Inc., Hanove...

1. A method of establishing operational settings for a plasma arc cutting system, the method comprising:
providing a plasma power supply with a user selectable control;
enabling a plurality of cutting personas with the user selectable control, each cutting persona comprising a set of parameters
customized for a particular kind of cut each cutting persona including at least: (1) a current, (2) a gas pressure or a gas
flow rate, and (3) at least one parameter of an operational mode; and

selecting one of the cutting personas from the plurality of cutting personas via the user-selectable control, thereby setting
each of the parameters within the set of parameters defined by the cutting persona in one action to minimize operator activity.

US Pat. No. 9,148,053

FLUX SATURATION CONTROLLER

Hypertherm, Inc., Hanove...

1. A high frequency transformer link converter comprising:
a high frequency transformer;
a primary controller arranged to provide a pulse width modulated (PWM) drive signal to the high frequency transformer;
at least two switch devices arranged to receive the PWM drive signal within the high frequency transformer, at least one of
the switch devices being arranged to reverse a polarity of transformer flux; and

a transformer flux controller, coupled to the at least two switch devices and uncoupled from the primary controller, the transformer
flux controller arranged to steer the PWM drive signal to direct the switch devices to maintain or reverse the polarity of
the transformer flux in response to detection of an onset of flux saturation in the high frequency transformer.

US Pat. No. 9,480,139

PLASMA ARC TORCH ELECTRODE WITH SYMMETRICAL PLASMA GAS FLOW

Hypertherm, Inc., Hanove...

1. An electrode for a plasma arc torch comprising:
a generally cylindrical elongated body formed of an electrically conductive material having a proximal end and a distal end;
an emissive insert disposed at the distal end of the electrode body;
a spiral flow passage disposed about a first surface relative to the proximal end of the elongated body, the spiral flow passage
configured to direct a cooling gas flow about the first surface of the elongated body, the cooling gas flow separated from
a plasma gas flow, the cooling gas flow and the plasma gas flow from a supply gas flow; and

a flange disposed between the spiral flow passage and the distal end of the elongated body, the flange extending radially
from a second surface of the elongated body, the flange and the spiral flow passage defining a volume therebetween and configured
to increase turbulence and mixing of the supply gas flow within the volume, thereby establishing a substantially symmetrical
gas flow distribution of the plasma gas flow about the distal end of the elongated body.

US Pat. No. 9,346,147

PEDESTAL STYLE WATERJET ORIFICE ASSEMBLY

HYPERTHERM, INC., Hanove...

1. An orifice assembly for a liquid jet cutting system, the orifice assembly comprising:
a base having a bottom surface and a top surface, the base defining a base conduit generally parallel to a central axis of
the orifice assembly, the base including a pedestal defining a protrusion from the top surface, the pedestal including a planar
top region being at least substantially perpendicular to the base conduit; and

an orifice structure disposed on the planar top region of the top surface of the base, the orifice structure defining an intermediate
conduit therethrough, the intermediate conduit aligned with and in fluid communication with the base conduit, the intermediate
conduit at least substantially perpendicular to the planar top region and parallel to the central axis of the orifice assembly.

US Pat. No. 9,522,438

BATTERY-CONTROLLED PLASMA ARC TORCH SYSTEM

Hypertherm, Inc., Hanove...

1. A method for operating a plasma arc torch system having a power supply and a plasma arc torch, the method comprising:
supplying power to the power supply from a battery, wherein the battery provides at least a portion of the power to generate
a plasma arc by the plasma arc torch;

supplying operating power to the plasma arc torch from the power supply;
communicating a first signal, indicating at least one parameter of the battery including a temperature of the battery, between
the battery and a plasma control circuit of a control unit, wherein the plasma control circuit is coupled to the power supply;

generating a second signal, by a battery control circuit of the control unit, based on the at least one parameter of the battery,
wherein the battery control circuit is coupled to the battery;

lowering, using the plasma control circuit, the operating power supplied to the plasma arc torch based on the second signal
when the temperature of the battery is below a threshold to maintain the plasma arc; and

increasing, using the plasma control circuit, the operating power supplied to the plasma arc torch based on the second signal
when the temperature of the battery exceeds the threshold to maintain the plasma arc.

US Pat. No. 9,516,738

PLASMA TORCH ELECTRODE MATERIALS AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. An electrode for a plasma arc torch, the electrode comprising:
a body formed of an electrically conductive material, the body having a first end and a second end; and
an emissive portion comprising a multi-metallic insert disposed within the first end, the multi-metallic insert including
at least two non-oxidized metallic materials combined into a two-phase alloy, one of the non-oxidized metallic materials being
about 5 weight percent to about 50 weight percent of metallic yttrium.

US Pat. No. 9,497,845

CONSUMABLES FOR A PLASMA ARC TORCH FOR BEVEL CUTTING

Hypertherm, Inc., Hanove...

1. A consumable set usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece, the consumable
set comprising:
a nozzle including: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice disposed
in the nozzle body for constricting the plasma arc, wherein the nozzle exit orifice defines an exit orifice axis oriented
at a non-zero bevel angle relative to the longitudinal axis;

a substantially planar alignment surface defined by an external surface of the nozzle, the alignment surface being generally
parallel to the longitudinal axis, wherein the substantially planar alignment surface is dimensioned to orient the plasma
arc torch generally perpendicular to the processing surface of the workpiece such that the nozzle exit orifice causes the
plasma arc to impinge on the processing surface of the workpiece at the non-zero bevel angle; and

a second alignment surface defined by a second external surface of the nozzle and disposed substantially orthogonal to the
substantially planar alignment surface, wherein the second alignment surface, in cooperation with the alignment surface, aligns
the plasma arc to impinge on the processing surface at the non-zero bevel angle while the plasma arc torch is substantially
perpendicular to the processing surface.

US Pat. No. 9,480,138

ARTICULATING THERMAL PROCESSING TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. An actuated, gantry-mounted mechanized plasma processing torch comprising:
a torch housing having a head portion pivotally coupled to a body portion;
a first pivot joint located between the head portion and the body portion, the first pivot joint pivoting along a first plane;
a first electrically conductive member conducting an electrical current across the first pivot joint;
a first interior gas passage to convey a processing gas across the first joint;
a second pivot joint located between the head portion and the first pivot joint, the second pivot joint pivoting along a second
plane;

a second electrically conductive member conducting an electrical current across the second pivot joint; and
a second interior gas passage to convey a processing gas across the second pivot joint,
wherein the first pivot joint is disposed at a substantially perpendicular angle from the second pivot joint about a longitudinal
axis of the body portion such that the actuated torch is configured to pivot the first pivot joint along the first plane that
is disposed at the substantially perpendicular angle from the second plane along which the second pivot joint pivots.

US Pat. No. 9,339,890

OPTIMIZATION AND CONTROL OF BEAM QUALITY FOR MATERIAL PROCESSING

Hypertherm, Inc., Hanove...

1. A method for adjusting a laser beam applied to a workpiece in a processing operation, the method comprising:
providing the laser beam to a laser processing system comprising an optical fiber, the laser beam being associated with a
beam quality property;

adjusting, by the laser processing system, the laser beam prior to the laser beam entering an input end of the optical fiber
to change the beam quality property of the laser beam exiting from an output end of the optical fiber,

wherein the adjusting of the laser beam at the input end of the optical fiber comprises at least one of displacing the laser
beam from a center of the input end of the optical fiber by a first amount, or changing an angle of the laser beam relative
to a longitudinal axis of the optical fiber by a second amount, wherein at least one of the first amount or the second amount
is based on at least one of (i) a thickness of the workpiece, or (ii) a material type of the workpiece; and

delivering the laser beam from the laser processing system to the workpiece.

US Pat. No. 9,560,732

HIGH ACCESS CONSUMABLES FOR A PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A nozzle for a plasma arc torch, the nozzle comprising:
a substantially hollow, elongated nozzle body capable of receiving an electrode, the body defining a longitudinal axis, a
distal end, and a proximal end, wherein the nozzle body includes a distal portion having a first internal cross-sectional
width and a proximal portion having a second internal cross-sectional width, the second internal cross-sectional width larger
than the first internal cross-sectional width;

a nozzle tip connected to the proximal end of the nozzle body, the nozzle tip including a nozzle exit orifice for introducing
a plasma arc to a workpiece, the nozzle body and the nozzle tip defining a conductive joint therebetween;

a swirl sleeve configured to impart a swirling motion to a gas introduced to the nozzle; wherein the first internal cross-sectional
width of the nozzle body and the nozzle tip cooperate to retain the swirl sleeve therebetween, preventing distal axial movement
of the swirl sleeve;

a nozzle shield; and
an insulator configured to connect the nozzle tip and the nozzle shield and to electrically insulate the nozzle shield and
the nozzle tip from one another while transferring thermal energy therebetween.

US Pat. No. 9,427,820

THERMAL TORCH LEAD GAS DELIVERY METHODS AND RELATED SYSTEMS AND DEVICES

Hypertherm, Inc., Hanove...

1. A method of initiating a plasma arc in a plasma cutting system, the method comprising:
providing a plasma gas supply lead line extending between a power supply and a plasma arc cutting torch, the lead line comprising
a first segment proximate to the power supply and a second segment proximate to the torch, and an in-line valve within the
lead line between the first segment and the second segment;

closing the in-line valve, by a controller, to capture a static volume of gas in the first segment;
establishing a volume of gas in the second segment having a decaying pressure; and
initiating the plasma arc when the decaying pressure of the volume of gas in the second segment reaches a pressure value within
a predetermined range while the in-line valve remains closed.

US Pat. No. 9,550,251

POWER SUPPLY ASSEMBLY FOR A PLASMA ARC TORCH SYSTEM

Hypertherm, Inc., Hanove...

1. A power supply assembly for a plasma arc torch, the power supply assembly comprising:
an input circuit configured to produce a first output signal, the input circuit including at least one of a boost circuit
or a rectification circuit;

an energy storage device electrically connected to an output of the input circuit for receiving a charge signal from the input
circuit, the energy storage device configured to produce a second output signal; and

a torch connector electrically connected to the input circuit and the energy storage device for receiving the first and second
output signals, wherein the torch connector is configured to supply the first output signal, the second output signal, or
a combination of the first and second output signals to the plasma arc torch to sustain a plasma arc based on comparing a
parameter of the plasma arc torch with at least one of the first or second output signal.

US Pat. No. 9,462,670

DIFFUSER SHAPE VENT SLOTS IN A HAND TORCH SHIELD CASTELLATION

Hypertherm, Inc., Hanove...

1. A torch tip for a plasma arc torch, the torch tip comprising:
a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch;
an end wall disposed at the second end of the body;
a plasma exit orifice formed in the end wall at the second end of the body;
at least two castellations formed in an exterior surface of the end wall, each castellation having a castellation width defined
by a distance between a first sidewall of each castellation and a second sidewall of each castellation at the second end of
the body;

at least one slot disposed between the two castellations, each slot having a slot floor and a slot width, and the slot width
being defined by a distance between the first sidewall of a first castellation and the second sidewall of a second castellation
adjacent the first castellation at the second end of the body, the slot width increasing with axial or radial distance away
from the plasma exit orifice;

wherein the slot width is at least twice the castellation width.

US Pat. No. 9,326,367

DEVICES FOR GAS COOLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A nozzle cooling system for a plasma arc torch comprising:
a nozzle having a body with a first end and a second end that define a longitudinal axis, a plenum region substantially formed
within the body, the plenum region extending from the first end of the body and configured to receive a plasma gas flow, an
exit orifice located at the second end of the body and oriented substantially coaxially with the longitudinal axis, the exit
orifice fluidly connected to the plenum region, and a feature on an outer surface of the body configured to increase cooling
by receiving a cooling gas flow flowing at high velocity generally in a direction of the longitudinal axis along a length
of the body, an impingement surface of the feature configured to receive the cooling gas flow at a substantially perpendicular
direction relative to the impingement surface and to redirect the cooling gas flow to promote cooling and uniform shield flow;
and

a nozzle retaining cap comprising a generally cylindrical body and a securing flange, the securing flange of the retaining
cap including a plurality of shield gas supply ports angled generally along the longitudinal axis of the nozzle at an angle
that is substantially perpendicular to the impingement surface of the feature of the nozzle.

US Pat. No. 9,642,237

METHOD OF IMPROVING ELECTRODE LIFE BY SIMULTANEOUSLY CONTROLLING PLASMA GAS COMPOSITION AND GAS FLOW

Hypertherm, Inc., Hanove...

1. A method of operating a plasma arc torch system, the method comprising:
providing (i) a plasma arc torch having a plasma chamber in which a plasma arc is generated, (ii) a first plasma gas supply
source and a second plasma gas supply source for providing a plasma gas flow to the plasma arc torch, and (iii) a control
unit for controlling cutting parameters including plasma gas composition and plasma gas flow path;

flowing a first plasma gas composition through a first plasma gas flow path during an arc ignition period;
generating the plasma arc using the first plasma gas composition;
changing the first plasma gas composition to a second plasma gas composition after the plasma arc is generated;
changing the first plasma gas flow path to a second plasma gas flow path after the plasma arc is generated, the second plasma
gas flow path different from the first plasma gas flow path; and

sustaining the plasma arc using the second plasma gas composition during a cutting period;
wherein the first and second plasma gas flow paths both are at least partially disposed within the plasma arc torch.

US Pat. No. 9,395,715

IDENTIFYING COMPONENTS IN A MATERIAL PROCESSING SYSTEM

Hypertherm, Inc., Hanove...

1. An automated material processing system for processing a workpiece using a processing table, the system comprising:
a replaceable component comprising at least one cutting head consumable, the replaceable component configured for mounting
on the processing table;

one or more radio frequency identification (RFID) signal devices disposed in or on the replaceable component, wherein the
one or more signal devices are encoded with information about the replaceable component that identifies two or more of a name,
trademark, manufacturer, serial number, usage history, operating parameter, or type associated with the replaceable component;

at least one reader communicatively connected to the one or more signal devices, the at least one reader configured to sense
the information encoded on the one or more signal devices; and

a computing device communicatively connected to the at least one reader for (i) processing the information transmitted by
the reader and (ii) configuring a set of operating parameters of the material processing system based on the sensed information
to operate the material processing system in a manner suitable for the replaceable component, the configuring including adjusting
a motion setting of the processing table based on the sensed information.

US Pat. No. 9,781,818

ASYMMETRIC CONSUMABLES FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A consumable set usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece for cutting
the workpiece, the consumable set comprising:
a nozzle including: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice, disposed
in the nozzle body, for constricting the plasma arc, wherein the nozzle exit orifice defines an exit orifice axis oriented
at a non-zero angle relative to the longitudinal axis; and

a planar alignment surface generally parallel to the exit orifice axis, the alignment surface being dimensioned to align the
exit orifice such that the plasma arc impinges orthogonally on the processing surface of the workpiece to cut the workpiece;
and

an opening at an exterior end of the nozzle exit orifice, wherein a center of the opening of the nozzle exit orifice is less
than about 0.25 inches from the alignment surface.

US Pat. No. 9,781,816

INTERCHANGEABLE POWER CONTACT FOR A PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A plasma arc torch for a liquid-cooled plasma arc cutting system comprising:
an upper torch assembly defining an aperture;
a lower torch assembly including a power contact thread region, wherein at least one of the upper torch assembly or the lower
torch assembly includes a first anti-rotation feature; and

a power contact for connecting the upper torch assembly with the lower torch assembly, the power contact including:
an external surface configured to matingly engage the upper torch assembly via insertion into the aperture, the power contact
being slideably removable from the upper torch assembly;

an internal thread surface configured to matingly engage the lower torch assembly via the power contact thread region of the
lower torch assembly, and

a second anti-rotation feature disposed on the external surface and adapted to complement the first anti-rotation feature
to prevent rotation of the lower torch assembly relative to the upper torch assembly.

US Pat. No. 9,643,273

SYSTEMS AND METHODS FOR CONFIGURING A CUTTING OR WELDING DELIVERY DEVICE

Hypertherm, Inc., Hanove...

1. A system for configuring a delivery device of a cutting or welding apparatus, the system comprising:
a determination module for determining at least one desired component of the delivery device or a value for at least one operating
parameter of the cutting or welding apparatus;

a mobile computing device comprising:
a receiver for receiving information from the determination module including at least one of i) identification of the desired
component or ii) the value of the operating parameter and (iii) a desired operation of the cutting or welding apparatus;

a reader for reading an element associated with a selected component, wherein the element provides indicia of at least one
characteristic of the selected component; and

a processor for approving the selected component for assembly into the delivery device if the indicia matches the identification
of the desired component or satisfies the value for the at least one operating parameter,

wherein the mobile device is configured to present a percentage usage remaining for the selected component normalized with
respect to the desired operation.

US Pat. No. 9,492,883

ELECTRODE FOR A CONTACT START PLASMA ARC TORCH AND CONTACT START PLASMA ARC TORCH EMPLOYING SUCH ELECTRODES

Hypertherm, Inc., Hanove...

1. A component for a contact start plasma arc torch, the component comprising:
a hollow body defining a channel with a longitudinal axis, the channel capable of slideably receiving an electrode body along
the longitudinal axis; and

a contact element disposed in the hollow body and includes a first surface and a second surface, the first surface facilitating
electrical communication with a power supply and the second surface physically contacting a surface of the electrode body
when the plasma arc torch is operated in a transferred arc mode, wherein the second surface is characterized by the absence
of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.

US Pat. No. 9,708,208

ENERGY PRODUCTION WITH HYPERTHERMOPHILIC ORGANISMS

HYPERTHERMICS HOLDING AS,...

1. A method comprising:
a) providing an algal biomass and a population of hyperthermophilic Thermatoga spp.;

b) degrading said biomass in the presence of said population of hyperthermophilic Thermatoga spp. at a temperature of above 80° C. under conditions such that degradation products are produced.

US Pat. No. 9,642,236

THREAD CONNECTION FOR A TORCH SYSTEM

Hypertherm, Inc., Hanove...

1. A connector component configured for coupling an electrode to a plasma arc torch, the connected component adapted to secure
to a corresponding component of another element of the plasma arc torch to attach the electrode to the other element, the
connector component comprising:
a body including a proximal end and a distal end disposed along a longitudinal axis;
at least two thread regions disposed radially about the longitudinal axis on a surface of the body near the proximal end,
wherein each thread region includes at least one thread disposed on the surface of the body; and

at least two smooth regions each disposed radially about the longitudinal axis between a pair of thread regions on the surface
of the body,

wherein the at least one thread in a first thread region of the at least two thread regions does not create a continuous rotational
thread path with the at least one thread of an adjacent thread region of the at least two thread regions, and

wherein at least one of the smooth regions of the connector component is configured to align with at least one of the thread
regions of the corresponding component of the other element to facilitate slidable displacement of the connector component
and the corresponding component relative to each other.

US Pat. No. 9,672,460

CONFIGURING SIGNAL DEVICES IN THERMAL PROCESSING SYSTEMS

Hypertherm, Inc., Hanove...

1. A consumable for a material processing head for orienting and positioning a ring-shaped radio-frequency identification
(RFID) tag within a material processing head, the consumable comprising:
a body that is substantially axially symmetric about a central longitudinal axis; and
the ring-shaped RFID tag attached to the body, the RFID tag having a central axis that is substantially coaxial to the central
longitudinal axis of the body, the RFID tag comprising a conductive coil formed around the central axis of the RFID tag and
disposed at least partially about the central longitudinal axis of the body,

wherein the conductive coil aligns with an antenna of an RFID reader located inside of the material processing head to receive
an induce tag current from the RFID reader, thereby reducing communication interference between the RFID tag and the RFID
reader inside of the material processing head.

US Pat. No. 9,662,747

COMPOSITE CONSUMABLES FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. An electrode for use in a plasma arc torch, the electrode comprising:
an elongated forward portion, defining a proximal end and a distal end, configured to provide an electrically conductive path
from the distal end to the proximal end, the forward portion comprising a first conductive material;

a ring-shaped aft portion, defining a hollow center, configured to substantially surround a portion of the forward portion
when the forward portion is located inside of the hollow center, wherein (1) the aft portion includes a pneumatic reaction
region disposed on a radially-extensive segment of the aft portion for receiving a biasing flow of a pressurized gas and separating
the electrode from a nozzle during pilot arc initiation (2) the aft portion comprises a second material that is different
from the first material; and

an emitter disposed in the proximal end of the forward portion.

US Pat. No. 9,630,272

IDENTIFYING PLASMA ARC TORCH COMPONENTS AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A method for operating a plasma cutting system, the method comprising:
initiating, in pilot arc mode, an arc between a set of consumable components disposed in a torch of the plasma cutting system,
the set of consumable components including a first consumable component and a second consumable component;

detecting an operational characteristic of the arc in the pilot arc mode;
analyzing the operational characteristic to identify at least one consumable component of the set of consumable components;
and

configuring, upon initiation, at least one operating parameter for the plasma cutting system based on the identified consumable
component to operate the plasma cutting system in a cutting mode with the identified consumable component.

US Pat. No. 9,630,273

WORKPIECE EDGE DETECTION USING PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A computer program product, tangibly embodied in a non-transitory, computer-readable storage device, for identifying an
edge of a workpiece, the computer program product including instructions operable to cause an automated cutting system to:
receive trace data for a test path to be traced over the workpiece;
flow a gas from a torch of the automated cutting system;
control the torch in accordance with the trace data to trace the test path over the workpiece;
obtain a set of back pressure values by monitoring a back pressure of the gas during the tracing of the path;
map the set of back pressure values to a set of coordinates; and
identify an edge of the workpiece using the set of back pressure values and the set of coordinates.

US Pat. No. 9,817,411

APPARATUS AND METHOD FOR OPTIMAL SELECTION OF CONSUMABLES IN A MATERIAL PROCESSING SYSTEM

Hypertherm, Inc., Hanove...

1. A method for configuring a thermal processing system to perform a processing operation, the method comprising:
receiving, from a user, information relating to a proposed processing operation to be performed by the thermal processing
system;

responsive to the information received from the user, determining two or more consumable component configurations for performing
the proposed processing operation;

estimating processing performance capabilities associated with using each of the consumable component configuration, the estimated
processing performance capabilities including at least of cutting time, cutting speed, cutting cost, or overall life of consumable
of the consumable component configuration; and

presenting for selection by the user, via a display associated with the thermal processing system, the estimated processing
performance capabilities for the two or more consumable component configurations; and

selecting, by the user, one of the consumable component configurations for the processing operation.

US Pat. No. 9,782,852

PLASMA TORCH WITH LCD DISPLAY WITH SETTINGS ADJUSTMENT AND FAULT DIAGNOSIS

Hypertherm, Inc., Hanove...

1. A plasma arc cutting system comprising:
a power supply;
a plasma torch attachable to the power supply to generate a plasma arc;
an identification device located on a cartridge or a consumable component of the plasma arc cutting system, the identification
device containing information establishing necessary operating parameters such that the power supply requires no further user
controls when the plasma torch uses automatically established operating parameters;

a reader associated with the plasma torch and capable of reading stored data from the identification device
a controller within the plasma arc cutting system and in communication with the reader and the power supply, the controller
capable of automatically establishing operating parameters of the plasma arc cutting system based upon the data stored on
the identification device;

a switch means, in communication with the power supply and activatable by a user of the plasma arc cutting system, for toggling
between the automatically established operating parameters and a set of user-selected operating parameters; and

a means for storing at least one of the operating parameters last manually entered into the plasma arc cutting system by the
user, the means for storing disposed in the power supply and in communication with the controller.

US Pat. No. 9,950,387

PLASMA TORCH POWER CIRCUIT AND COOLING SYSTEM

Hypertherm, Inc., Hanove...

1. A plasma arc cutting system comprising:a power supply configured to support generation of a plasma arc, the power supply including a multi-pulse transformer and a plurality of semiconductor switches directly connected to a bank of capacitors; and
a thermal regulation system connected to the power supply and configured to cool the multi-pulse transformer, the thermal regulation system further comprising:
a cold plate in contact with the semiconductor switches;
a fluid conduit disposed within the cold plate; and
a pump connected to the conduit and configured to direct a coolant fluid through the conduit,
wherein the power supply has at least one of the following operating requirements:
(i) a weight to power ratio of 22.4 pounds per kilowatt;
(ii) a volume to power ratio of 1366 cubic inches per kilowatt;
(iii) an average chopper semiconductor device case temperature of 100 degrees Centigrade during a cutting operation;
(iv) a maximum transformer temperature of about 133 degrees Centigrade during a cutting operation.

US Pat. No. 9,737,954

AUTOMATICALLY SENSING CONSUMABLE COMPONENTS IN THERMAL PROCESSING SYSTEMS

Hypertherm, Inc., Hanove...

1. A plasma arc torch for use in a plasma cutting system, the plasma arc torch comprising:
a torch body for conducting electrical current, the torch body including a torch tip configured to pass the electrical current
to at least one consumable component connected to the tip;

at least one antenna positioned relative to the torch tip, the antenna used to wirelessly detect a presence of the at least
one consumable component; and

a detection circuit configured to permit passing of the electrical current from the torch tip to the at least one consumable
component based on at least the wireless detection.

US Pat. No. 9,867,268

COOLING PLASMA TORCH NOZZLES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A nozzle for a plasma arc torch, the nozzle comprising:
a first body having a first tip end, a second end, and a longitudinal axis, the first body comprising an axial alignment flange
having i) a proximal surface configured to mate with a torch body of the plasma arc torch and to position the nozzle axially
within the torch and ii) an opposing distal surface exposed to liquid coolant flow; and

a second body disposed about a portion of the first body to complement the first body, the second body comprising a set of
axial features extending inwardly from an internal surface of the second body, the axial features having a radial height sufficient
to contact the first body and being shaped to form a coolant loop of a set of longitudinal liquid flow passages between the
first body and the second body,

the second body at least partially defining at least one radial coolant inlet and at least one radial coolant outlet to the
set of longitudinal liquid flow passages, the at least one radial coolant inlet and at least one radial coolant outlet being
defined at or near a proximal end of the second body, the distal surface of the alignment flange and an annular channel defined
at the proximal end of the second body together forming the at least one inlet; and

a fluid seal formed between the first body and the second body at or near the first tip end to limit liquid within the coolant
loop from exiting the nozzle at the tip end of the nozzle.

US Pat. No. 9,820,371

SYSTEMS AND METHODS FOR STABILIZING PLASMA GAS FLOW IN A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A nozzle of a plasma arc torch, the nozzle configured to reduce fluid pressure surging in a nozzle plenum, the nozzle comprising:
a nozzle body having a proximal end and a distal end, the nozzle plenum defined between the nozzle body and an electrode of
the plasma arc torch;

a nozzle plenum gas inlet located at the proximal end of the nozzle body;
a plasma gas exit orifice located at the distal end of the nozzle body;
a plasma gas passageway fluidly connecting the nozzle plenum gas inlet to the plasma gas exit orifice; and
an isolation chamber having a common inlet and outlet fluidly connected to the plasma gas passageway and the nozzle plenum,
the isolation chamber sized to receive a volume of substantially stagnant gas to reduce the fluid pressure surging in the
nozzle plenum.

US Pat. No. 9,789,561

APPARATUS AND METHOD FOR A LIQUID COOLED SHIELD FOR IMPROVED PIERCING PERFORMANCE

Hypertherm, Inc., Hanove...

1. A shield for a plasma arc torch that pierces and cuts a metallic workpiece producing a splattering of molten metal directed
toward the torch, the shield configured to cover and protect at least a nozzle and a nozzle retaining cap of the plasma arc
torch from the splattering molten metal and to be replaced independently of the nozzle, the shield comprising:
a generally conical unitary body defining an interior surface to form a gas flow path with an outer surface of an adjacent
nozzle of the plasma arc torch and an exterior surface, the body comprising:

a distal first portion defining an exit orifice and having: i) a substantially conical exterior surface region exposed to
the molten metal and formed along the exterior surface of the body, and ii) an interior surface region to be contacted by
a cooling shield gas flow within the gas flow path along the interior surface of the body to cool the nozzle and the shield;
and

a proximal second portion formed of a flange sharing a common surface with the distal first portion having one or more surface
regions to be directly cooled by a liquid coolant flow along the common surface shared with at least one of the exterior surface
of the body or the interior surface of the body,

the exterior surface region of the distal first portion being conductively cooled by the direct liquid cooling of the flange
along a thermally conductive path formed through a continuous conductively cooled region so as to limit the molten metal splatter
from bonding to the exterior surface of the distal first portion, at least a portion of the conductively cooled region disposed
adjacent the flange; and

a seal assembly disposed on the common surface shared between the flange of the proximal second portion and the distal first
portion along the unitary body to retain the liquid coolant flow along the proximal second portion, to limit leakage of the
liquid coolant flow from the plasma arc torch, and limit the liquid coolant flow from contacting the nozzle.

US Pat. No. 9,967,964

COOLING PLASMA CUTTING SYSTEM CONSUMABLES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. An electrode for a plasma cutting system, the electrode comprising:an arc portion shaped to matingly engage a nozzle of the plasma cutting system, the arc portion having a first end comprising a plasma arc emitter disposed at a distal end thereof; and
a thermal portion in thermal communication with a second end of the arc portion, the thermal portion shaped to slidingly engage a complementary swirl ring of the plasma cutting system and including:
a first circumferentially formed disk-shaped flange mating feature extending radially from a proximal end of the thermal portion of the electrode, the first circumferentially formed disk shaped flange mating feature defining a first radial width to physically mate with the swirl ring, the first circumferentially formed disk-shaped flange mating feature including a sealing member adapted to form a dynamic seal with the swirl ring to prevent a gas from traveling proximally between the electrode and the swirl ring,
a second circumferentially formed disk-shaped flange mating feature extending radially from a distal end of the thermal portion of the electrode to define a second radial width to physically mate with the swirl ring, wherein the first radial width and the second radial width are substantially equal, and
a thermal exchange surface region between the first disk-shaped flange mating feature and the second disk-shaped flange mating feature, the thermal exchange surface defining at least one annular flange extending from the thermal portion between the first circumferentially formed disk-shaped flange mating feature and the second circumferentially formed disk-shaped flange mating feature, the at least one annular flange having a radial width less than at least one of the first radial width and the second radial width.

US Pat. No. 9,900,972

PLASMA ARC CUTTING SYSTEMS, CONSUMABLES AND OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. A liquid-injection shield for a plasma torch, the shield comprising:
a body having an exterior surface and an interior surface; and
a liquid injection regulation component circumferentially disposed within and in direct contact with the interior surface
of the body, the liquid injection regulation component and the interior surface of the body defining a chamber,

the liquid injection regulation component defining a first set of ports, included within the liquid regulation component and
sized to regulate a liquid entering the chamber and defining a second set of ports, included within the liquid injection regulation
component and oriented to distribute a fluid exiting the chamber, and

wherein a total cross-sectional flow area of the first set of ports is less than a total cross-sectional flow area of the
second set of ports.

US Pat. No. 9,981,335

CONSUMABLE CARTRIDGE FOR A PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A replaceable cartridge for a plasma arc torch, the replaceable cartridge comprising:a replaceable cartridge body having a first section, configured to mate with the plasma arc torch, and a second section including an exit orifice of an arc constricting member that forms a part of the second section, the first and second sections securely affixed at an interface to form a substantially hollow chamber, the interface providing a coupling force that secures the first and second sections together;
an electrode slidably positioned and irremovably disposed within the substantially hollow chamber; and
a contact start spring element located within the substantially hollow chamber of the replaceable cartridge body and in physical contact with the first section of the replaceable cartridge, the spring element imparting a separating force on the electrode that biases the electrode toward the second section of the plasma arc torch in a direction along an axis of the replaceable cartridge, the separating force having a magnitude that is less than a magnitude of the coupling force,
wherein the cartridge is a single unit that is configured to be replaced as a unit after it reaches the end of the life of any constituent component of the cartridge.

US Pat. No. 9,908,195

PLASMA CUTTING SYSTEM WITH EFFICIENT COMPONENTS

Hypertherm, Inc., Hanove...

1. A plasma cutting system comprising:
an enclosure including:
a power source located in the enclosure and configured to generate a plasma arc; and
a compressor located in the enclosure and operably connected to the power source for generating a gas supply to the plasma
cutting system;

a plasma arc cutting torch connected to the power source for delivering the plasma arc to cut a workpiece at a distal end
of the torch, the torch comprising a swirl ring, an electrode, a nozzle, and a plasma chamber defined by the electrode and
the nozzle; and

a circumferential seal formed between the electrode and the swirl ring of the torch, the circumferential seal configured to
prevent the gas supply from traveling in a reverse flow direction toward a proximal end of the torch away from the workpiece,

wherein the plasma arc cutting torch further comprises a second circumferential seal formed between the swirl ring and a retaining
cap to engage an external surface of the swirl ring to an internal surface of the retaining cap,

wherein the plasma arc cutting torch defines a multi-function fluid flow path that receives the gas supply from the compressor
for sustaining the plasma arc and cooling the plasma arc cutting torch, the multi-function fluid flow path channeling the
gas supply in a substantially forward direction through a proximal swirl ring inlet to an electrode cooling passage located
between an external surface of the electrode and an inner surface of the swirl ring, the multi-function fluid flow path exiting
the electrode cooling passage by a distal swirl ring outlet to flow toward the distal end of the torch, such that the plasma
cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm) of the gas supply
that is supplied from the compressor to the plasma arc cutting torch.

US Pat. No. 10,039,178

FAILURE EVENT DETECTION IN A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A method of determining a failure event of consumable for a plasma torch, the method comprising:monitoring, during operation of the plasma torch, at least one signal comprising an operating current or an operating voltage;
determining whether the plasma torch is being operated in a transfer arc mode; and
performing, when the plasma torch is operating in the transfer arc mode, steps including:
filtering, during the transfer arc mode, the at least one signal using a high-pass filter to remove a low-frequency component of the at least one signal, thereby generating at least one filtered signal;
setting a fault flag to indicate a potential consumable failure when a parameter of the at least one filtered signal exceeds and does not fall below a tolerance threshold during a predetermined time period, wherein the tolerance threshold corresponds to a predetermined success rate for capturing consumable failure; and
shutting off at least one of the operating current or the operating voltage of the plasma arc torch during the transfer arc mode when the fault flag is set to indicate the potential consumable failure.

US Pat. No. 10,129,969

ARC CUTTING SYSTEM, INCLUDING COOLANT TUBES AND OTHER CONSUMABLES, AND RELATED OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

16. A universal coolant tube for a liquid cooled plasma arc torch, the coolant tube comprising:a hollow, elongated coolant tube body including a proximal end, a distal end, and a longitudinal axis extending therethrough, the coolant tube body configured to provide a coolant flow to an electrode of the plasma arc torch;
a flared portion at the distal end of the coolant tube;
a plurality of feet at the distal end of the flared portion, the plurality of feet configured to physically contact an interior surface of the electrode;
an O-ring at the proximal end of the coolant tube; and
a radial extensive portion located between the proximal end of the coolant tube and the O-ring and configured to be axially biased toward the electrode, wherein the radial extensive portion includes a radial alignment surface that is at least 0.25 inches in length along the longitudinal axis.

US Pat. No. 9,989,054

COMPACT ULTRAHIGH PRESSURE DYNAMIC SEAL ASSEMBLY WITH PRESSURE ACTIVATING BACKUP RING

Hypertherm, Inc., Hanove...

1. A seal assembly for a high pressure liquid system, the seal assembly comprising:a seal carrier including a base portion defining a proximal end and a distal end, the seal carrier defining a bore and having a surface for mating to a pump cylinder, the pump cylinder having a plunger for pressurizing a volume of liquid within a bore of the pump cylinder on a pressure stroke;
a seal disposed within the bore of the seal carrier;
a backup ring disposed within the bore of the seal carrier;
a hoop ring disposed-between the seal and the backup ring, the hoop ring having a proximal surface and an outer surface;
an o-ring disposed between a portion of the seal carrier and the seal,
wherein the distal end of the seal carrier includes a tapered portion and the o-ring is located in the tapered portion of the seal carrier.

US Pat. No. 10,098,217

COMPOSITE CONSUMABLES FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. An electrode for use in a plasma arc torch, the electrode comprising:an elongated forward portion, defining a proximal end and a distal end, configured to provide an electrically conductive path from the distal end to the proximal end, the forward portion comprising a first conductive material with a first density;
a ring-shaped aft portion, defining a hollow center, configured to substantially surround and attach to a portion of the forward portion, a portion of the forward portion being located inside of the hollow center, the aft portion comprising a second conductive material with a second density, wherein the second density is at least two times less than the density of the first material;
an emitter disposed in the proximal end of the forward portion;
a contact element located at the distal end of the forward portion; and
a resilient element located between the contact element and the ring-shaped aft portion and physically contacting the forward portion, the ring-shaped aft portion coupling to the forward portion and adapted to move as one piece with the forward portion, the resilient element biasing the ring-shaped aft portion and the forward portion away from the contact element, wherein the resilient element passes at least a portion of a transferred arc current between a power supply and the forward portion via the contact element during a transferred arc operation of the plasma arc torch.

US Pat. No. 10,149,376

WATER INJECTION AND VENTING OF A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A plasma arc torch system having a supply system including a liquid source for supplying a liquid, and a liquid supply conduit in fluid communication with a liquid passageway between a nozzle and a shield of a plasma arc torch to introduce the liquid from the liquid source to a flow region of a plasma arc torch, thereby surrounding the plasma arc with the liquid, the plasma arc torch including:an electrode;
the nozzle spaced from the electrode to define a plasma chamber therebetween, the nozzle comprising a nozzle body, a nozzle exit orifice, and a vent outlet, wherein the plasma chamber is configured to receive a plasma gas;
a vent passage disposed in the nozzle body configured to divert a portion of the plasma gas exiting the plasma chamber to the vent outlet, thereby constricting the plasma arc; and
a shield spaced from the nozzle to define the liquid passageway and the flow region therebetween, the shield comprising a shield exit orifice in fluid communication with the nozzle exit orifice, wherein the liquid passageway is configured to receive the liquid and introduce the liquid having a liquid swirl strength to the flow region such that the liquid surrounds and constricts the plasma arc, and the flow region is configured to expel the liquid along with the plasma arc surrounded by the liquid at the shield exit orifice,
wherein diverting the portion of the plasma gas by the vent passage in the nozzle and expelling the liquid at the shield exit orifice both provide constriction of the plasma arc.

US Pat. No. 10,194,516

HIGH ACCESS CONSUMABLES FOR A PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A plasma torch extender for a plasma arc cutting system, the plasma torch extender comprising:an elongated body including a semi-rigid, positionable flexible section having an axis extending between a first end and a second end, the flexible section having a length of at least six inches and sufficient stiffness and ductility to enable manipulation at any point along its axis to form a three-dimensional bent axis, the flexible section adapted to be poseable across a plurality of orientations including at least a first movement spanning at least 90 degrees, between the first end and the second end, such that when manipulated the three-dimensional bent axis remains fixed;
a first connector at the first end of the elongated body directly connectible to a consumable set; and
a second connector at the second end of the elongated body directly connectible to a torch mount.

US Pat. No. 10,194,517

PLASMA ARC CUTTING SYSTEM, CONSUMABLES AND OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. An electrode for a liquid cooled plasma arc torch, the electrode comprising:a body having a longitudinal axis defining a first end, a second end, and a middle portion between the first and second ends;
a first sealing element disposed on an exterior of the body near the first end of the body, the first sealing element configured to provide a liquid seal;
a second sealing element disposed on the exterior of the body, the second sealing element located in the middle portion between the first sealing element and the second end of the body along the longitudinal axis, the second sealing element configured to provide a first gas seal to a swirl gas chamber and defining a portion of the swirl gas chamber; and
a third sealing element disposed on the exterior of the body, the third sealing element located between the second sealing element and the second end of the body along the longitudinal axis, the third sealing element configured to provide a second gas seal to the swirl gas chamber and defining a portion of the swirl gas chamber.