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. 9,107,282

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. 9,510,436

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. 9,736,918

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. 9,144,148

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. 9,144,882

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. 9,516,738

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. 9,148,053

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. 9,522,438

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. 9,346,147

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. 9,782,852

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. 9,497,845

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. 9,481,050

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. 9,339,890

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. 9,427,820

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. 9,560,732

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. 9,480,138

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. 9,480,139

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. 9,462,670

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. 9,395,715

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. 9,708,208

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. 9,326,367

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. 9,550,251

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. 9,642,237

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. 9,643,273

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. 9,781,818

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. 9,737,954

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. 9,642,236

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. 9,781,816

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. 9,867,268

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. 9,672,460

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. 9,492,883

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. 9,662,747

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. 9,950,387

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. 9,817,411

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. 9,630,272

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. 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. 10,039,178

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. 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. 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. 9,967,964

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. 10,299,363

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; 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 form a surface-to-surface seal between the first body and the second body, the axial features being shaped to form a set of longitudinal liquid flow passages forming a coolant loop between the first body and the second body,
the second body at least partially defining at least one coolant inlet and at least one coolant outlet to the set of longitudinal liquid flow passages; 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,
the set of liquid flow passages defined by the axial features being configured to:
receive a liquid coolant from the at least one inlet;
direct the liquid coolant distally between the first body and second body toward the tip end; and
direct the liquid coolant around the axial features to reverse direction and flow proximally away from the tip end and expel the liquid coolant from between the first body and second body through the at least one outlet.

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.

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. 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. 10,321,551

COST EFFECTIVE CARTRIDGE FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A consumable cartridge for a plasma arc torch, the consumable cartridge comprising:an outer component defining a substantially hollow body;
an inner component disposed substantially within the hollow body of the outer component, the inner component comprising:
a forward portion configured to axially secure and rotatatably engage the outer component with respect to the forward portion of the inner component; and
a rear portion substantially suspended within and without being in direct physical contact with the hollow body of the outer component, the rear portion axially secured and rotatably engaged with respect to the outer component via the forward portion; and
a hollow region between the rear portion of the inner component and the outer component, the hollow region configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

US Pat. No. 10,314,155

ASYMMETRIC CONSUMABLES FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A torch tip assembly of a plasma arc torch for delivering a diffused stream of plasma arc to a workpiece to perform a gouging operation, the assembly comprising:a nozzle including (i) a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end, (ii) a chamber in the nozzle body for receiving an electrode at the proximal end, and (iii) a nozzle exit orifice at the distal end of the nozzle body, the nozzle exit orifice defining at least a bore for conducting the plasma arc therethrough, the bore being disposed distally relative to the chamber, the bore having a first cross-sectional shape in a plane parallel to the longitudinal axis and a second cross-sectional shape in a plane perpendicular to the longitudinal axis; and
a counter bore being fluidly connected to the chamber via the bore that is between the counter bore and the chamber, the counter bore located along the central longitudinal axis, the counter bore having a first cross-sectional shape in the plane parallel to the longitudinal axis and a second cross-sectional shape in the plane perpendicular to the longitudinal axis, the first cross-sectional shape of the counter bore being substantially rectangular;
wherein at least one of the second cross-sectional shape of the bore or the second cross-sectional shape of the counter bore is non-circular, the at least one second non-circular cross-sectional shape of the bore or counter bore configured to facilitate a non-circular cross-sectional shape of the plasma arc adapted to diffuse the plasma arc in the workpiece; and
wherein an area of the second cross-sectional shape of the counter bore at a proximal end of the counter bore is greater than an area of the second cross-sectional shape of the bore at a distal end of the bore.

US Pat. No. 10,455,682

OPTIMIZATION AND CONTROL OF MATERIAL PROCESSING USING A THERMAL PROCESSING TORCH

Hypertherm, Inc., Hanove...

1. A consumable component of a thermal processing torch that includes a receiver disposed inside of the thermal processing torch, the consumable component comprising:a consumable component body; and
a signal device, comprising a radio-frequency identification (RFID) tag, located on or within the consumable component body for transmitting a signal associated with the consumable component, the signal being independent of a detectable physical characteristic of the consumable component,
the signal device being configured to store information to be conveyed by the signal identifying two or more of the consumable's name, trademark, manufacturer, serial number, usage history, at least one operating parameter, and type, and
the signal device being located inside of the thermal processing torch when the consumable component is installed in the thermal processing torch and the signal device being configured to allow the signal to be readable by the receiver inside the thermal processing torch.

US Pat. No. 10,278,274

CARTRIDGE FOR A LIQUID-COOLED PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A consumable cartridge frame for a liquid-cooled plasma arc torch, the consumable cartridge frame comprising:a plastic insulator body configured to be a portion of a torch cartridge, a proximal region of the insulator body removably connectable to a torch head and a distal region of the insulator body connectable to a cartridge tip that includes a nozzle and a shield;
a first cooling channel, disposed in and defined by the insulator body, configured to align with a flow region in the nozzle of the cartridge tip to conduct a first fluid flow received from the torch head from the proximal region to the distal region of the insulator body to cool the nozzle of the cartridge tip connected to the insulator body; and
a first return channel, disposed in and defined by the insulator body, configured to conduct at least a portion of the first fluid flow from the nozzle at the distal region to the proximal region of the insulator body connected to the torch head;
a second cooling channel, disposed in and defined by the insulator body, configured to align with a flow region of the shield of the cartridge tip to conduct at least a portion of the first fluid flow from the proximal region to the distal region of the insulator body to cool the shield connected to the insulator body; and
a second return channel, disposed in and defined by the insulator body, configured to align with the flow region of the shield to conduct at least a portion of the first fluid flow from the shield at the distal region to the proximal region of the insulator body connected to the torch head,
wherein the first cooling channel, the second cooling channel, the first return channel and the second return channel are non-concentric in relation to a central longitudinal axis of the insulator body, the first cooling and return channels and the second cooling and return channels are defined between the proximal and distal regions of the insulator body.

US Pat. No. 10,561,009

CARTRIDGE FOR A LIQUID-COOLED PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A liquid-cooled consumable cartridge for a plasma arc torch, the cartridge comprising:an electrode;
a swirl ring with a first outer retaining feature and a second outer retaining feature on an exterior surface, wherein the electrode is secured to the swirl ring;
a nozzle with an inner retaining feature on an interior surface, wherein the inner retaining feature of the nozzle is mated with the first outer retaining feature of the swirl ring;
a cartridge frame with an inner retaining feature on an interior surface and an outer retaining feature on an exterior surface, wherein the inner retaining feature of the cartridge frame is mated with the second outer retaining feature of the swirl ring; and
a shield with an inner retaining feature on an interior surface mated with the outer retaining feature of the cartridge frame,
wherein the cartridge frame comprises at least one liquid flow path disposed therein, the liquid flow path being radially offset from a central longitudinal axis of the cartridge frame.

US Pat. No. 10,279,417

CONTROLLING AND DELIVERING GASES IN A PLASMA ARC TORCH AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A torch receptacle for coupling a plasma arc torch to a torch lead of a plasma cutting system, the torch receptacle comprising:a body having a first end shaped to connect to the torch lead and a second end shaped to connect to a torch body or a torch tip of the plasma arc torch;
a pair of entry ports disposed at the first end of the body and configured to fluidly connect to a set of fluid conduits disposed within the torch lead; and
a multiway valve having at least two inlets and an outlet disposed within the body and fluidly connected to the pair of entry ports at the first end of the body and to a torch gas conduit disposed at the second end of the body, the multiway valve being configured to select between a first plasma gas and a second plasma gas entering the pair of entry ports by selectively blocking a flow of either the first plasma gas or the second plasma gas entering the body, thereby delivering a selected plasma gas through the torch body to the torch gas conduit to supply the plasma arc torch.

US Pat. No. 10,245,674

SYSTEMS AND METHODS FOR PLASMA GAS VENTING IN A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A plasma cutting system comprising:a torch body having a proximal end and a distal end defining a longitudinal axis extending therethrough;
a torch tip having a proximal end and a distal end, the torch tip located at the distal end of the torch body and including a plasma plenum and a plasma arc exit orifice located at the distal end of the torch tip;
a lead connector disposed on the proximal end of the torch body and connectable to a torch lead at the proximal end of the torch body, the torch lead having a proximal end and a distal end;
an atmospheric vent port from the plasma plenum and disposed between the plasma arc exit orifice and the distal end of the torch lead, the atmospheric vent port having an outer opening exposed to atmosphere, the outer opening disposed upstream of the proximal end of the torch tip and downstream of the distal end of the torch lead; and
a conduit fluidly connecting the plasma plenum and the atmospheric vent port, the conduit comprising:
a first channel configured to direct a portion of ionized gas from the plasma plenum in a first direction axially away from the plasma arc exit orifice; and
a second channel, fluidly connected between the first channel and the atmospheric vent port, configured to direct the portion of ionized gas from the first channel to the atmospheric vent port.

US Pat. No. 10,561,010

INTERNALLY ENERGIZED ELECTRODE OF A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A coolant tube for a plasma arc torch, the coolant tube comprising:an elongated coolant tube body, made from an electrically conductive material, including a first end configured to engage an electrode and a second end configured to engage a body of the plasma arc torch;
a first electrically conductive element coupled to the first end of the elongated coolant tube body, the first electrically conductive element being resilient and configured to physically contact the electrode; and
a second electrically conductive element coupled to the second end of the elongated coolant tube body, the second electrically conductive element being resilient and configured to physically contact the body of the plasma arc torch;
wherein the elongated coolant tube body defines a current path and a fluid path between the body of the plasma arc torch and the electrode,
and wherein substantially all of a current from the body of the plasma arc torch is passed to the electrode via the conductive coolant tube through (i) a first physical interface formed between the body of the plasma arc torch and the second electrically conductive element that is coupled to the coolant tube and (ii) a second physical interface between the electrode and the first electrically conductive element that is coupled to the coolant tube, without passing the current directly from the body of the plasma arc torch to the electrode.

US Pat. No. 10,462,891

COST EFFECTIVE CARTRIDGE FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A crown for a plasma arc torch, the crown comprising:a body defining a distal end that is closest to a workpiece during an operation of the plasma arc torch and a proximal end opposite of the distal end, the distal end of the body disposed adjacent to and aligned with a proximal end of an electrode of the plasma arc torch;
at least one raised feature at the proximal end of the body, the raised feature adapted to depress a consumable sensor inside of the plasma arc torch to permit a flow of electrical current from a power supply; and
a surface of the body having one of (i) a depressed center to conduct the electrical current through the body, or (ii) an opening adapted to provide the electrical current to the electrode.

US Pat. No. 10,335,888

SWIRL RING AND CONTACT ELEMENT FOR A PLASMA ARC TORCH CARTRIDGE

Hypertherm, Inc., Hanove...

1. A cartridge frame for mating with a plasma arc torch having a cartridge sensing switch and one or more consumables seated in the frame of the plasma arc torch during operation, the cartridge frame comprising:a body configured to at least partially surround and slidingly engage an electrode of the plasma arc torch, the body including a first end and a second end nearest the torch and opposite the first end, the first and second ends defining a longitudinal axis, and at least one discrete protuberance extending from the second end of the body in a direction of the longitudinal axis,
wherein the at least one protuberance is configured to mechanically engage the cartridge sensing switch of the plasma arc torch during operation of the plasma arc torch.

US Pat. No. 10,492,286

PLASMA ARC CUTTING SYSTEM, INCLUDING RETAINING CAPS, AND OTHER CONSUMABLES, AND RELATED OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. An inner cap for a liquid-cooled plasma arc torch, the inner cap comprising:a substantially hollow body having a longitudinal axis, a first end, and a second end, the first end including an annular portion configured to be disposed proximate a torch tip of the plasma arc torch;
a liquid passage formed within the body and shaped to convey a liquid therethrough, the liquid passage including a first set of fluid exit ports formed in the annular portion; and
a gas passage formed within the body and shaped to convey a gas therethrough, the gas passage including a second set of fluid exit ports formed in the annular portion,
wherein the annular portion is configured such that subsets of ports in the first set of fluid exit ports direct the liquid out of the inner cap in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of fluid exit ports that direct the gas out of the inner cap in a direction substantially parallel with the longitudinal axis,
wherein the first and second sets of fluid exit ports are spaced circumferentially around the annular portion and are positioned perpendicular or substantially perpendicular to each other to create a cross-flow of liquid and gas in the annular portion during operation of the torch.

US Pat. No. 10,346,647

CONFIGURING SIGNAL DEVICES IN THERMAL PROCESSING SYSTEMS

Hypertherm, Inc., Hanove...

1. A material processing head for reducing communication interference between data tags and an antenna, the material processing head comprising:a body;
the antenna disposed within the body;
a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and
a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency,
wherein the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic of the flux communication zone in which the first tag and/or the second tag is disposed.

US Pat. No. 10,624,198

CONTROLLING GAS FLOWS TO PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A computer-implemented method for controlling a pneumatic system in a plasma arc processing system power supply, the method comprising:receiving, by a computing device disposed within the plasma arc processing system power supply, a command to begin a plasma processing operation;
generating, by the computing device, a valve command signal for a valve within the plasma power supply, the generating the valve command signal including supplying to the valve, an operational drive voltage of at least about 125% of a continuous duty cycle coil voltage rating of the valve to open the valve; and
once the valve is open, adjusting, by the computing device, the valve command signal to facilitate a steady state operation of the valve, the adjusting comprising:
monitoring a steady state operational duty cycle of the valve, the steady state operational duty cycle being determined by comparing the continuous duty cycle coil voltage rating of the valve to an actual operational drive voltage supplied to the valve, and
controlling the operational drive voltage supplied to the valve, based on the monitoring, to maintain the steady state operational duty cycle of the valve at less than about 60% of a continuous duty cycle coil voltage rating of the valve during steady state operation.

US Pat. No. 10,413,991

SUPPLYING PRESSURIZED GAS TO PLASMA ARC TORCH CONSUMABLES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A consumable for a plasma arc torch that generates a predetermined plenum pressure from a substantially constant preset gas supply pressure from a plasma arc torch power supply, the substantially constant preset gas supply being used to support plasma generation for a selection of multiple consumable components that each generate a different plasma plenum pressure for carrying out different processes, the consumable comprising:a proximal portion shaped to connect to the plasma arc torch and define a gas inlet, wherein the gas inlet is fluidly connected to the substantially constant preset gas supply;
a distal portion shaped to define a gas outlet, wherein the gas outlet is fluidly connected to the gas inlet by at least one flow path, the flow path including at least the gas inlet, the gas outlet, and a pressure matching stage, the pressure-matching stage defined between the gas inlet and the gas outlet,
the pressure-matching stage comprising a pressure wall and at least one metering hole
wherein the at least one metering hole and the pressure wall are configured to reduce a cross sectional flow area of the at least one flow path, thereby establishing sufficient fixed pressure drop of a flow of gas flowing through the pressure-matching stage to reduce the substantially constant preset gas supply pressure of the flow of gas to the predetermined plenum pressure.

US Pat. No. 10,555,410

CARTRIDGE FOR A LIQUID-COOLED PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A consumable cartridge for a liquid-cooled plasma arc cutting torch, the consumable cartridge comprising:a cartridge tip located at a first portion of the cartridge, the cartridge tip having an electrode, a nozzle, and a shield; and
a cartridge frame at a second portion of the cartridge, the cartridge frame comprising a distal end connected to the cartridge tip, a proximal end, and a body defining a central longitudinal axis extending between the proximal and distal ends, the cartridge frame including:
a plasma gas inlet opening at the proximal end configured to maintain fluid communication with the nozzle to introduce a plasma gas flow to the nozzle;
a shield gas inlet opening at the proximal end configured to maintain fluid communication with the shield to introduce a shield gas flow to the shield;
an electrode coolant inlet opening at the proximal end configured to maintain at least one of electrical or fluid communication with the electrode to introduce at least one of a liquid coolant or electrical current to the electrode;
a nozzle coolant inlet opening and a nozzle coolant outlet opening at the proximal end configured to circulate at least a portion of the liquid coolant between the cartridge frame and the nozzle; and
a shield coolant inlet opening and a shield coolant outlet opening at the proximal end configured to circulate at least a portion of the liquid coolant between the cartridge frame and the shield,
wherein the plasma gas inlet opening, the shield gas inlet opening, the nozzle coolant inlet opening, the nozzle coolant outlet opening, the shield coolant inlet opening and the shield coolant outlet opening are radially non-concentric about and radially offset from the central longitudinal axis.

US Pat. No. 10,549,383

HIGHLY POSITIONED LASER PROCESSING NOZZLE

Hypertherm, Inc., Hanove...

1. A double nozzle for a laser processing head, the double nozzle comprising:an inner body portion configured to assist transport of a first fluid flow from the laser processing head toward an exit orifice of the double nozzle, the inner body portion having an interior surface defining a first bore, a first exterior circumferential surface disposed toward a distal end of the inner body portion, and a second exterior circumferential surface disposed toward a proximal end of the inner body portion, the second exterior circumferential surface shaped to mate and align with the laser processing head; and
an outer body portion having an interior surface defining a second bore, the outer body portion matingly engaged with the first exterior circumferential surface of the inner body portion and isolated from direct alignment contact with the laser processing head, the second bore configured to assist transport of a second fluid flow that circumferentially surrounds the first fluid flow,
wherein the inner body portion and the outer body portion are aligned to define a coaxial fluid flow path therethrough.

US Pat. No. 10,525,554

WATER COOLING OF LASER COMPONENTS

Hypertherm, Inc., Hanove...

1. A thermal regulation device configured to engage a laser cutting head having a separable laser cutting nozzle, the thermal regulation device comprising:a body shaped to matingly engage a separable laser cutting nozzle that directly confines a laser beam and to define a fluid flow boundary of a liquid flow passage between an exterior surface of an interior circumference of the body and an exterior surface of the laser cutting nozzle when the thermal regulation device is affixed to the laser cutting nozzle, the body shaped to substantially circumferentially enclose a central portion of the laser processing nozzle;
an inlet formed in a first end of the body and configured to provide liquid to the liquid flow passage, the liquid flow passage configured to keep the liquid remaining external to an exterior surface of the laser cutting nozzle; and
an outlet formed in a second end of the body opposite the first end, the outlet configured to exhaust liquid from the liquid flow passage.

US Pat. No. 10,486,260

SYSTEMS, METHODS, AND DEVICES FOR TRANSMITTING INFORMATION TO THERMAL PROCESSING SYSTEMS

Hypertherm, Inc., Hanove...

1. A replaceable consumable component of a torch tip in a thermal processing torch for performing a cutting operation, the thermal processing torch in electrical communication with a power supply located external to the thermal processing torch, the replaceable consumable component of the torch tip in the thermal processing torch comprising:a body; and
a readable data storage device, comprising a radio-frequency identification (RFID) tag, integrated with the body, the readable data storage device includes an operation instruction for operating the thermal processing torch,
wherein (i) the readable data storage device is inserted within the thermal processing torch upon installation of the replaceable consumable component in the thermal processing torch and (ii) the readable data storage device is positioned on the body to maintain an unobstructed signal communication path to an RFID reader and is readable by the RFID reader from inside of the thermal processing torch.

US Pat. No. 10,456,855

CONSUMABLE CARTRIDGE FOR A PLASMA ARC CUTTING SYSTEM

Hypertherm, Inc., Hanove...

1. A metallic frame for a replaceable, unitary cartridge configured for installation into a plasma arc cutting torch, the metallic frame comprising:a first end connected to a nozzle, and a second end configured to mate with an electrode, the metallic frame surrounding and inseparably securing the electrode in electrical isolation from the metallic frame and the nozzle;
a set of flow passages built into the metallic frame, the set of flow passages fluidly connecting an internal surface of the metallic frame and an external surface of the metallic frame, the set of flow passages radially offset to impart a swirling fluid flow pattern to gases flowing therethrough; and
a plasma gas exit orifice for constricting exiting plasma gas, the plasma gas exit orifice included within, or in direct physical communication with, the nozzle, wherein the set of flow passages is oriented toward the plasma gas exit orifice.

US Pat. No. 10,681,799

PLASMA ARC CUTTING SYSTEM, INCLUDING NOZZLES AND OTHER CONSUMABLES, AND RELATED OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. A nozzle for a liquid-cooled plasma arc torch, the nozzle comprising:a thermally conductive body having a distal end, a proximal end, and a longitudinal axis extending therethrough;
a plasma arc exit orifice at the distal end of the thermally conductive body;
a cooling waist located on an external surface of the body and disposed circumferentially about the exterior surface, the cooling waist including a liquid inlet slope, a liquid outlet slope and a heat exchange region between the liquid inlet slope and the liquid outlet slope, wherein the heat exchange region extends substantially parallel to the longitudinal axis, and wherein the liquid inlet slope and the liquid outlet slope are oriented generally perpendicular to the longitudinal axis such that the liquid inlet and outlet slopes extend radially outward from the external surface of the body while being disposed circumferentially about the external surface;
a first sealing member located on the external surface between the liquid outlet slope and the distal end of the thermally conductive body; and
a second sealing member located on the external surface between the proximal end of the thermally conductive body and the liquid inlet slope.

US Pat. No. 10,569,360

HIGHLY POSITIONED LASER PROCESSING NOZZLE

Hypertherm, Inc., Hanove...

1. A double nozzle for a laser processing head, the double nozzle comprising:an inner body portion having (i) an interior surface defining a first bore, and (ii) an exterior surface, the bore aligned with a central longitudinal axis of the body; and
an outer body portion having an interior surface defining a second bore that is substantially aligned to the longitudinal axis, the outer body portion matingly engaged with a region of the exterior surface of the inner body portion,
wherein the region between the exterior surface of the inner body portion and the interior surface of the outer body portion defines at least six coaxial fluid flow paths through an interior annular flow volume of the double nozzle, each fluid flow path defined at least in part by a corresponding feature formed in at least one of the inner body portion or the outer body portion.

US Pat. No. 10,645,791

SWIRL RING FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A swirl ring for a plasma arc torch, the swirl ring comprising:a hollow body having a distal end and a proximal end and configured to receive at least a portion of an electrode within the hollow body, the proximal end configured to attach to a torch body of the plasma arc torch and the distal end configured to attach to a nozzle of the plasma arc torch, the hollow body defining a longitudinal axis extending from the proximal end to the distal end;
a first set of flange segments circumferentially disposed on an interior surface of the hollow body, the first set of flange segments extending radially inward from the interior surface and shaped to retain a first surface of a sealing member; and
a second set of flange segments circumferentially disposed on the interior surface of the hollow body, the second set of flange segments extending radially inward from the interior surface and shaped to retain a second surface of the sealing member,
wherein (i) the second set of flange segments are spaced distally from the first set of flange segments along the longitudinal axis, and (ii) flange segments of the second set of flange segments are radially offset from flange segments of the first set of flange segments.

US Pat. No. 10,638,591

PLASMA ARC CUTTING SYSTEM, INCLUDING SWIRL RINGS, AND OTHER CONSUMABLES, AND RELATED OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. A plasma gas swirl ring for a liquid cooled plasma arc torch, the swirl ring comprising:a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface, the distal and the proximal ends of the body defining a longitudinal axis extending therethrough, wherein the interior region of the body is configured to receive an electrode of the plasma arc torch;
a first opening disposed within a portion of the proximal end of the body, the first opening configured to provide fluid communication from the interior region to the exterior surface of the body;
a second opening disposed about a central portion of the body, the second opening configured to provide fluid communication from the exterior surface to the interior region of the body; and
a third opening comprising at least one swirling port disposed within a portion of the distal end of the body, the third opening oriented substantially parallel to the longitudinal axis, the third opening fluidly connecting the interior region of the body to an exterior region, the third opening configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.

US Pat. No. 10,542,614

APPARATUS AND METHOD FOR SECURING A PLASMA TORCH ELECTRODE

Hypertherm, Inc., Hanove...

4. An electrode for a plasma arc torch including a cathodic power block, the electrode comprising:an electrically conductive body having an outermost diameter, a first end and a second end, the first end having a receptacle and the second end of the conductive body configured to receive an emissive element; and
a contact element in electrical communication with the first end of the conductive body of the electrode, the contact element comprising:
a proximal end having a head portion comprising a torch body contact surface configured to receive a torch current from the cathodic power block of the torch;
a seating portion having an outer width greater than the outermost diameter of the electrode body, the outer width having a mating surface comprising a contour, step or flange that facilitates mating with a complementary mating surface at a proximal opening of a swirl ring, the seating portion configured to conform the contact element with and engage the contact element to the proximal opening of the swirl ring, such that the contact element is (i) fixedly secured between the cathodic power block and the proximal opening of the swirl ring and (ii) positioned relative to the proximal opening of the swirl ring within the plasma arc torch; and
a distal portion of the contact element comprising a contact surface configured to moveably engage with the electrode body and to provide the torch current to the first end of the conductive body and a neck portion having an elongated body with a central axis that aligns with a central axis of the electrode body, the neck portion of the contact element configured to moveably engage the conductive body of the electrode within the receptacle at the first end of the electrode body, thereby aligning the contact element and the swirl ring with the central axis of the electrode body to reduce misalignment by restraining radial movement and improving cut performance
wherein the electrode, the cathodic power block and the swirl ring are components of the plasma arc torch.

US Pat. No. 10,562,125

CONTROLLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A method for preserving a usable life of a plasma arc electrode consumable installed in a plasma arc torch, the method comprising:measuring, with a control system, a pulse width modulation characteristic of an electrical signal being provided to the torch to generate a plasma arc between the torch and a workpiece to be processed, wherein the pulse width modulation characteristic comprises at least one of a pulse width modulation value, a rate of change of the pulse width modulation value, or a pulse width modulation duty cycle;
determining, with the control system, a pulse width modulation threshold value corresponding to the pulse width modulation characteristic based on a plurality of cutting operation parameters, wherein the plurality of cutting operation parameters comprises at least one consisting from the group of workpiece material type, workpiece material thickness, cutting speed, or cutting operation;
monitoring, with the control system, the pulse width modulation characteristic during operation of the torch over a time period;
comparing, with the control system, the pulse width modulation characteristic to the pulse width modulation threshold value; and
responsive to determining that a measured pulse width modulation characteristic meets and/or exceeds the pulse width modulation threshold value, initiating an arc extinguishing sequence to preserve the life of the electrode.

US Pat. No. 10,716,199

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

Hypertherm, Inc., Hanove...

1. A shield for an air-cooled plasma arc torch, the shield comprising:a body having a proximal end configured to mate with a torch body of the plasma arc torch, a distal end, and a central longitudinal axis defined between the proximal end and the distal end;
an exit orifice formed in the distal end of the body;
an interior of the shield comprising an interior shield flow surface that forms a portion of a shield gas flow channel, the shield gas flow channel directing a flow of shield gas along the interior shield flow surface in a flow direction from the proximal end to the exit orifice at the distal end of the body;
a flow directing flange extending from the body and away from the exit orifice in the distal end of the body, the flange being formed annularly around the central longitudinal axis and defining a first outer annular surface and an opposing second inner annular surface that is between the first outer annular surface and the exit orifice; and
an annular flow impingement surface, disposed between the interior shield flow surface and the first outer annular surface of the flange, that disrupts the flow direction of shield gas flowing towards the distal end of the body and directs the flow of shield gas proximally along the first outer annular surface of the flange into a continuous annularly formed flow path defined by a circumferentially formed complementary recess of a corresponding nozzle thereby distributing the flow of shield gas substantially uniformly about the complementary recess,
the opposing second inner annular surface of the flange being configured to receive the substantially uniform flow of shield gas being re-directed and flowing distally from the circumferentially formed recess of the corresponding nozzle and out of the exit orifice.

US Pat. No. 10,716,200

PLASMA ARC CUTTING SYSTEM, INCLUDING RETAINING CAPS, AND OTHER CONSUMABLES, AND RELATED OPERATIONAL METHODS

Hypertherm, Inc., Hanove...

1. A liquid cooled shield assembly for a plasma arc torch, the liquid cooled shield assembly comprising:an inner cap including:
a substantially hollow body having a proximal end and a distal end that define a longitudinal axis, the distal end including an annular portion about the longitudinal axis; and
a liquid passage defined, at least in part, by an interior surface of the body, the liquid passage including a first set of ports in the annular portion including three or more discreet, circumferentially disposed radial liquid exit ports, the first set of ports extending between an interior portion of the body and an exterior portion of the body to convey a cooling liquid out of the liquid exit ports in a radial direction with respect to the longitudinal axis;
and
a shield at least partially surrounding the inner cap and having a liquid impingement region on an interior surface of the shield adjacent to the first set of liquid exit ports, the liquid impingement region for (i) receiving the cooling liquid from the first set of liquid exit ports, and (ii) forming part of a liquid exit channel in the plasma arc torch.

US Pat. No. 10,539,942

CONTROLLING PLASMA ARC PROCESSING SYSTEMS AND RELATED SYSTEMS AND DEVICES

Hypertherm, Inc., Hanove...

1. An autonomous motion device configured to operably connect to a plasma torch of a plasma arc processing system, the autonomous motion device comprising:a body to support a power supply of the plasma processing system and move relative to a workpiece;
a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed;
a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation;
a set of one or more sensors configured to monitor at least one characteristic of the plasma processing operation or the translation of the body relative to the workpiece; and
a processor in communication with the drive system and configured to communicate with the power supply and the set of sensors, the processor being configured to receive feedback from the set of sensors to control the translation of the body relative to the workpiece and to communicate with the plasma arc processing system to update one or more cutting parameters during the plasma processing operation, the one or more cutting parameters not including torch positioning instructions.

US Pat. No. 10,609,805

CARTRIDGE FOR A LIQUID-COOLED PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A torch head for a liquid-cooled plasma arc torch, the torch head comprising:a torch body; and
a torch insulator having a substantially non-electrically-conductive insulator body, the torch insulator coupled to the torch body, the torch insulator including:
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;
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
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,
wherein the first and second preexisting flow paths are fluidly isolated from each other, and wherein the first liquid coolant channel and the first liquid return channel are radially non-concentric about and radially offset in relation to a central longitudinal axis of the insulator body.

US Pat. No. 10,736,204

PLASMA POWER TOOL

Hypertherm, Inc., Hanove...

1. A hand-held plasma power tool comprising:a plasma delivery tip section for delivering a plasma arc to a workpiece to cut the workpiece;
an air compressor for providing a gas of less than about 50 standard cubic feet per hour (scfh) to the plasma delivery tip section;
a power source for providing a current of between about 6 amps to about 10 amps to at least one of the air compressor or the plasma delivery tip section; and
a hand-held housing, wherein at least a portion of the plasma delivery tip section, the air compressor, and the power source are enclosed within the housing, and wherein at least a portion of the housing defines a handle section being configured to enable an operator to hold the entirety of the plasma power tool by hand while delivering the plasma arc to the workpiece.

US Pat. No. 10,582,605

COST EFFECTIVE CARTRIDGE FOR A PLASMA ARC TORCH

Hypertherm, Inc., Hanove...

1. A cartridge for an air-cooled plasma arc torch, the cartridge comprising:a swirl ring including:
a molded thermoplastic elongated body having a substantially hollow portion, the molded thermoplastic elongated body having a distal end and a proximal end and configured to receive an electrode within the hollow portion, the elongated body defining a longitudinal axis extending between the proximal and distal end;
a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch; and
a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body; and
an electrically conductive cap affixed to the proximal end of the elongated body of the swirl ring, the cap substantially covering the proximal end of the elongated body along a radial plane perpendicular to the longitudinal axis.

US Pat. No. 10,620,079

DETECTING FLUID LEAKS IN PRESSURIZED SYSTEMS OF WATERJET CUTTING SYSTEMS

Hypertherm, Inc., Hanove...

1. A waterjet cutting pressurization system, the system comprising:a water pump: (i) having a pressurization chamber and (ii) having a high-pressure water seal maintaining water pressure within the chamber; and
a leak detector in fluid communication with the high-pressure water seal and configured to monitor a leak rate of a fluid from the high-pressure water seal, wherein the leak detector is configured to measure a temperature of the fluid.

US Pat. No. 10,610,983

COOLING PLASMA CUTTING SYSTEMS AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A power supply for a liquid cooled plasma cutting system configured to support generation of a plasma arc by a torch head connected to the power supply by a torch lead, the power supply comprising:a power supply housing containing a set of electrical components for plasma arc generation, the power supply housing having a front panel, a rear panel, at least two side panels, and at least one angled corner, wherein the front panel, rear panel, and at least two side panels define normal surfaces of the power supply housing and the at least one angled corner is beveled with respect to one of the at least two side panels and at least one of the front or rear panels, the power supply housing defining:
a set of inlets for allowing a cooling gas to enter the power supply housing to thermally regulate the set of electrical components, at least one inlet of the set of inlets being positioned at the at least one angled corner of the housing;
a set of vents for allowing at least a portion of the cooling gas to exit the power supply housing;
a set of cooling circuits, each cooling circuit fluidly connected to the set of inlets and the set of vents, each cooling circuit substantially fluidly separate from each other; and
wherein individual electrical components of the set of electrical components are positioned within a higher capacity cooling circuit or a lower capacity cooling circuit, such that cooling requirements of the individual electrical components in the higher capacity cooling circuit are greater than cooling requirements of the individual electrical components in the lower capacity cooling circuit.

US Pat. No. 10,575,985

METHOD AND APPARATUS FOR CONTROLLING THE INNER TEMPERATURE OF A PATIENT

Vither Hyperthermia B.V.,...

1. A method for controlling the inner temperature of a patient, the method comprising the steps of:creating a fluid circuit that comprises the patient and a heat exchanger, a power supply thereto being controlled by a controller;
subjecting at least a portion of a fluid in said fluid circuit to the heat exchanger;
directing the subjected fluid to and into the patient to control the inner temperature of the patient;
estimating a temperature of an organ of the patient at a time t by a model comprising a parametric correlation function of the temperature of the organ and a number of input parameters, wherein the parametric correlation function, including a calibration of the parameters of the correlation function, has been obtained on an animal other than the patient; and
controlling the power supply to the heat exchanger such that the estimated organ temperature remains below an upper threshold organ temperature and/or above a lower threshold organ temperature, wherein the parametric correlation function for one temperature sensor “i” is given by one of the following:
Torgan(t)=Ci+fskin·Tskin+fi·Tisensor+1/M?fj·P(?tj)  (I)
wherein
Torgan (t)=organ temperature at time t;
Ci=a parameter constant for sensor “i” (° C.);
fskin=a parameter constant (?);
Tskin=the measured skin temperature (° C.);
fi=a parameter constant (?) for the ith temperature sensor;
Tisensor=the measured temperature of the ith temperature sensor (° C.);
M=body mass of the animal (kg);
?fj·P(?tj)=a weighted sum of heat outputs of the heat exchanger in time intervals ?tj=tj?tj-1 to prior to time t with fj=parameter constant for each jth time interval;
Torgan(t)=Ci+fi*Tisensor+1/M?fj·Q(t)·(Tfin?Tfout)dt  (II)
wherein
Torgan(t)=organ temperature at time t;
Ci=a parameter constant for sensor “i” (° C.);
fi=a parameter constant (?) for the ith temperature sensor;
Tisensor=the measured temperature of the ith temperature sensor (° C.);
M=body mass of the animal (kg);
?fj·Q(t)·(Tfin?Tfout) dt=the integral from tj to tj-1 of the product of the fluid flow Q (in m3/sec) and the temperature difference between a measured temperature Tfin of the fluid (° C.) when entering the body and a measured temperature Tfout of the fluid (° C.) when exiting the body in time intervals ?tj=tj?tj-1 to prior to time t with fj=parameter constant for each jth time interval; or
Torgan(t)=Ci+Testimate(0)+fi·(Tisensor?Ti0sensor)+1/M?fj·P(?tj)  (III)
wherein
Torgan (t)=organ temperature at time t;
Ci=a parameter constant for sensor “i” (° C.);
Testimate (0)=the estimated organ temperature at time 0;
fi=a parameter constant (?) for the ith temperature sensor;
Tisensor=the measured temperature of the ith temperature sensor (° C.);
Ti0sensor=the measured temperature of the ith temperature sensor (° C.) at time 0;
M=body mass of the animal (kg);
?fj·P(?tj)=a weighted sum of heat outputs of the heat exchanger in time intervals ?tj=tj?tj-1 to prior to time t with fj=parameter constant for each jth time interval.

US Pat. No. 10,654,149

ABRASIVE RECYCLING SYSTEM

Hypertherm, Inc., Hanove...

1. A liquid jet abrasive recycling system, the system comprising:a frame having a base structure that contacts a surface on which the system rests, wherein peripheral-most portions of the base structure that contacts the surface define a footprint perimeter of the system;
a slurry inlet supported by the frame, the slurry inlet configured to receive a slurry, the slurry containing a liquid, foreign particles, and an abrasive;
a dryer supported by the frame and configured to receive the slurry and remove the liquid therefrom to form a dry mixture;
an outlet in communication with the dryer to receive the dry mixture, an egress of the outlet being disposed in the footprint perimeter; and
an abrasive collector in communication with the outlet, the abrasive collector configured to collect the abrasive as it is released from the egress and within the footprint perimeter, wherein the abrasive collector is positioned within the footprint perimeter.

US Pat. No. 10,610,953

SYSTEMS AND METHODS FOR PROVIDING POWER FOR PLASMA ARC CUTTING

Hypertherm, Inc., Hanove...

1. A plasma cutting system comprising:a plasma torch comprising a head;
a housing; and
a power supply disposed within the housing and in communication with the plasma torch, the power supply configured to provide an output current for generating and maintaining a plasma cutting arc by the plasma torch, the power supply including:
one or more control processors; and
a plurality of autonomous switching circuits in communication with the one or more control processors via a multi-node communications bus, wherein each of the plurality of autonomous switching circuits comprises a unique identifier, each of the plurality of autonomous switching circuits including a microcontroller configured to:
control the generation of a portion of the output current based on one or more messages received from the one or more control processors;
monitor one or more operating parameters of the autonomous switching circuit; and
modify a control parameter of the autonomous switching circuit independent of and asynchronous to the other autonomous switching circuits of the plurality of autonomous switching circuits when one or more of the operating parameters exceeds a predetermined threshold,
wherein operation of an autonomous switching circuit of the plurality of autonomous switching circuits is enabled or disabled based on a value of its unique identifier.

US Pat. No. 10,576,575

THREAD CONNECTION FOR A TORCH SYSTEM

Hypertherm, Inc., Hanove...

1. A consumable connector component of a consumable of a material processing head for attaching the consumable to a corresponding component of the material processing head, the consumable connector component comprising:a cylindrical body including a proximal end and a distal end disposed along a longitudinal axis;
a plurality of segments disposed radially about the body, each segment including at least one thread disposed on a surface of the body; and
a plurality of smooth regions disposed radially about the surface of the body near the proximal end, each of the smooth regions radially located between a pair of the segments; and
wherein the at least one thread of a first segment of the plurality of segments forms a pitch path that is not rotationally continuous with a pitch path formed by the at least one thread of an adjacent segment of the plurality of segments.

US Pat. No. 10,772,183

DISABLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A plasma arc torch for a plasma cutting system, the plasma arc torch comprising:a torch grip;
an operator interface switch connected to a plasma control circuit: i) configured to control a current from the plasma cutting system through the plasma arc torch to one or more consumables disposed at a distal end of the torch grip and ii) configured to initiate generation of a plasma arc from a tip of the torch;
a cap sense switch disposed within the torch grip connected to the plasma control circuit and configured to detect a presence of one or more of the consumables, the cap sense switch further configured to open or close the plasma control circuit in accordance with the detection of the presence of the one or more consumables; and
a torch disable switch separate from the operator interface switch disposed on the torch grip and connected to the plasma control circuit, the torch disable switch including:
a plasma control circuit disconnect configured to selectively connect or disconnect the plasma control circuit to prevent current flow, including pilot current, to the one or more consumables, and
a user interface connected to the plasma control circuit disconnect, the user interface configured to operatively connect or disconnect the plasma control circuit with the plasma control circuit disconnect in response to an operator input.

US Pat. No. 10,713,448

CONFIGURING SIGNAL DEVICES IN THERMAL PROCESSING SYSTEMS

Hypertherm, Inc., Hanove...

1. A plasma processing system, comprising:a torch comprising a torch consumable;
a fluid delivery system including a supply gas pressure regulator and a supply pressure sensor configured to sense a supply pressure of an inlet flow to the supply gas pressure regulator;
a gas supply line supplying gas from the gas pressure regulator to the torch; and
a controller comprising a processor and a memory, wherein the controller is operatively connected to the gas pressure regulator and the supply pressure sensor to receive a pressure signal from the supply pressure sensor and to provide a control signal to the gas pressure regulator to set an output pressure of the gas pressure regulator,
wherein the memory stores a lookup table establishing a correlation between supply pressures to the supply gas pressure regulator and respective levels of the control signal for one or more consumables, wherein the controller is configured to identify the consumable based on the supply pressure to the gas pressure regulator and the control signal provided to the gas pressure regulator.

US Pat. No. 10,754,337

SYSTEMS AND METHODS FOR PLANNING PATHS TO GUIDE ROBOTS

Hypertherm, Inc., Hanove...

1. A computer-implemented method for guiding a robot in a robotic system, by creating a refined path, based on an initial path in a three-dimensional space, the method comprising:receiving, by a computing device, data related to creating the initial path, including a start point and an endpoint;
generating, by the computing device, the initial path by interpolating the start point and the endpoint, wherein generating the initial path comprises:
determining, by the computing device, a set of one or more polynomial functions to represent the initial path, wherein the set of one or more polynomial functions defines coordinates to model a route from the start point to the end point; and
displaying, by the computing device on a computerized display, the initial path in a virtual environment;
receiving, by the computing device, inputs for at least one support point on the initial path that defines a coordinate in the three-dimensional space for altering the initial path;
causing a control handle to appear on the computerized display for at least one of the start point, the endpoint or the support point, the control handle permitting a user to rotate or move the control handle in the three-dimensional space to change curvature of at least a portion of the initial path or the refined path;
adjusting, by the computing device, the initial path to generate the refined path by modifying the set of one or more polynomial functions, such that the refined path interpolates the at least one support point between the start point and the endpoint; and
providing, by the computing device, the refined path to a second computing module for guiding the robot.

US Pat. No. 10,737,347

THREAD CONNECTION FOR A TORCH SYSTEM

Hypertherm, Inc., Hanove...

1. A connector component configured for coupling a consumable component to a plasma arc torch, the connector component comprising:a body having a proximal end and a distal end disposed along and defining a longitudinal axis;
at least two engagement regions disposed radially about the longitudinal axis on a surface of the body, wherein each engagement region includes at least one engagement feature disposed on the surface of the body; and
at least two free regions disposed radially about the longitudinal axis on the surface of the body, each free region radially located between a pair of the engagement regions, each free region characterized by an absence of the engagement feature;
wherein the at least one engagement feature in a first engagement region of the at least two engagement regions creates a discontinuous rotational path with the at least one engagement feature of an adjacent engagement region of the at least two engagement regions, the at least one engagement feature of the first region includes a structure extending from the body that engages with a corresponding engagement feature of a corresponding connector component of the plasma arc torch.

US Pat. No. 10,723,025

COMPUTER-IMPLEMENTED METHODS AND SYSTEMS FOR GENERATING MATERIAL PROCESSING ROBOTIC TOOL PATHS

Hypertherm, Inc., Hanove...

1. A computer-implemented method for selecting a robotic tool path for a manufacturing processing system to execute a material processing sequence in three-dimensional space, the method comprising:providing to a computer a computer-readable product including robotic system data associated with physical parameters of a robotic tool handling system and workpiece data for a workpiece to be processed by the material processing system, the workpiece data relating to a processing path of a tool connected to the robotic tool handling system along the workpiece;
generating a start point and an end point of the processing path;
generating a plurality of possible robotic tool paths to be performed to move the tool along the processing path between the start point and the end point;
based on the robotic system data and/or the workpiece data, identifying one or more obstacles, or an absence of obstacles, associated with the robotic tool paths;
comparing robotic tool paths based on a predetermined robotic parameter to be controlled as the tool moves from the start point to the end point;
based on the identified obstacles, determining feasible tool paths, between the start point and the end point that avoid the obstacles, that can be obtained by adjusting the predetermined robotic parameter; and
selecting one of the determined feasible tool paths for a material processing sequence in order to form a part from the workpiece.

US Pat. No. 10,722,970

CONTROLLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A method for limiting damage to a torch body of a plasma arc torch resulting from an electrode blow-out within the plasma arc torch, the method comprising:determining, by a processor, a specified conductivity parameter set point of a current to be provided to the electrode for a material processing operation;
setting, by a pulse width modulation control system, the specified conductivity parameter set point;
determining, by the processor, a threshold amount indicating that blow-out of the electrode is impending,
measuring, by the processor, a detected conductivity parameter of plasma arc current being provided to the plasma torch to perform the material processing operation;
comparing, by the processor, the specified conductivity parameter set point to the detected conductivity parameter of plasma arc current and calculating an error term signal;
determining, by the processor, that the error term signal exceeds the threshold amount thereby representing the presence of an electrode fluid in the torch body and an impending blow-out of the electrode; and
initiating, an accelerated plasma arc shut down sequence before complete failure of the electrode, to abruptly extinguish the plasma arc to limit damage to the plasma arc torch body by limiting spatter caused by an electrode blow-out from flowing back into the torch body.

US Pat. No. 10,722,971

CONTROLLING PLASMA ARC TORCHES AND RELATED SYSTEMS AND METHODS

Hypertherm, Inc., Hanove...

1. A method of detecting a plasma arc of a plasma arc torch has pierced through a workpiece during a piercing sequence in order to begin a cutting sequence, the method comprising:calculating, by an at least one processor, a rate of change of a characteristic reflecting a pulse width modulation duty cycle associated with a plasma arc between an electrode of the plasma arc torch and the workpiece;
monitoring, by the at least one processor, the rate of change of the characteristic during an operation of the plasma arc torch over a time period of a piercing sequence;
comparing, by the at least one processor, the rate of change of the characteristic to a threshold value; and
ending the piercing sequence and commencing the cutting sequence by causing the plasma arc torch to move relative to the workpiece to form a cut, in response to determining, by the at least one processor, that the rate of change of the characteristic is equal to or greater than the threshold value, indicating that the plasma arc has pierced through the workpiece.

US Pat. No. 10,722,974

SYSTEM AND METHOD FOR PROCESSING PARTS ON A WORKPIECE

Hypertherm, Inc., Hanove...

1. A method for nesting parts on a workpiece, the method comprising:identifying characteristics of a workpiece to be processed;
nesting, by a computer controller, a first nest pattern of a local first part to be cut out of the workpiece, the first nest pattern being an optimal nesting pattern of the local first part;
identifying, by the computer controller, an unused portion of the workpiece not occupied by the first nest pattern;
querying, by the computer controller, a remote database to identify a remote second part to be cut, wherein the second part comprises material characteristics corresponding to the characteristics of the workpiece and is nestable in the unused portion of the workpiece;
using the computer controller to derive a calculation of a composite nesting pattern comprising the local first part and the remote second part to maximize material yield of the workpiece; and
adjusting the first nest pattern, based on the calculation, to nest the local first part and the remote second part on the workpiece such that the local first part and the remote second part are co-mingled in location within a portion of the workpiece.